Building panel assemblies and methods of use in wall structures

ABSTRACT

Light weight fiber-reinforced polymeric (FRP) structural building panels and panel assemblies, sized and configured for construction of non-portable wall structures permanently fixed to the ground. Fibers in the panel are typically oriented within 15 degrees of a top-to-bottom, e.g. axial, direction in the panel providing, in part, enhanced top-to-bottom crush strength of a panel/wall. The panels typically have a bias to deflect toward the surface of the panel which faces outwardly of the building, toward the backfill soil which faces the panel on the outside the building. Panels of the invention typically have mass of no more than 18 pounds per foot height per linear foot length of the building panel, and vertical crush resistance capacity of at least 2000 pounds per linear foot length of the building panel, using a safety factor of 3.

CROSS REFERENCES TO RELATED APPLICATIONS

This application is a Continuation-In-Part of U.S. patent applicationSer. No. 14/109,408, filed Dec. 17, 2013, which is aContinuation-In-Part of U.S. patent application Ser. No. 13/317,121,filed Oct. 11, 2011, which is a Continuation-In-Part of U.S. patentapplication Ser. No. 12/317,164, filed Dec. 18, 2008, and thisapplication is a Non-Provisional of U.S. Provisional Patent ApplicationSer. No. 61/404,793, filed Oct. 8, 2010, the entireties of the precedingapplications being incorporated herein by reference in their entireties.

BACKGROUND OF THE INVENTION

This invention relates to building systems which largely replace theupright uses of concrete, whether ready-mix concrete or pre-fabricatedconcrete blocks, or other pre-fabricated concrete products, inconstruction projects. In general, the invention relates to enclosedbuildings as well as other structures, and replaces the concrete inbelow-grade frost walls and foundation walls, and in above-grade walls.Such concrete structures are replaced, in the invention, with structuresbased on fiber-reinforced polymer materials (FRP) and the bottoms ofsuch FRP walls may be integrated with a concrete footer/floor.

Certain improvements in building construction, including buildingpanels, walls, buildings and appurtenances, methods of making buildingpanels, and methods of constructing walls, wall systems, and buildingsare taught in co-pending applications of common assignment as follows:

Ser. No. 11/901,174, filed Sep. 13, 2007;

Ser. No. 11/901,057, filed Sep. 13, 2007;

Ser. No. 11/900,987, filed Sep. 13, 2007;

Ser. No. 11/900,998, filed Sep. 13, 2007;

Ser. No. 11/901,059, filed Sep. 13, 2007;

Ser. No. 11/901,173, filed Sep. 13, 2007;

Ser. No. 11/901,175, filed Sep. 13, 2007;

Ser. No. 12/317,164, filed Dec. 18, 2008;

Ser. No. 61/571,290 filed Jun. 23, 2011;

Ser. No. 61/573,799 filed Sep. 12, 2011;

Ser. No. 14/109,408, filed Dec. 17, 2013;

all of the above being incorporated herein by reference, in theirentireties.

There has been a need, in the construction industry, for additionalimprovements in light weight structural building panels and buildingsystems incorporating such building panels. For example, generallycontinuous building panels of any desired length up to a maximum lengthper panel, may be selectable in length, in height, and in thickness,whereby such structural building panels may be used in applicationswhere concrete is conventionally used in residential, commercial, andindustrial construction. Such structural building panels should bestrong enough to bear the primary compressive loads and lateral loadswhich are imposed on the underlying walls in a building enclosure orother building structure.

In light of severe wind conditions, which occur periodically in somelocales, there is a need for building systems where overlying buildingstructure is securely anchored to an underlying wall structure such as afoundation, whereby attachments between the underlying foundation andthe overlying structure assist in preventing separation of the overlyingstructure from the foundation under severe wind conditions, and wherethe foundation wall is securely and automatically anchored to the footerby the process of creating the footer.

There is also a need for walls which are generally impermeable to water,including at joints in the wall.

These and other needs are alleviated, or at least attenuated, by thenovel construction products, and methods, and building systems of theinvention.

SUMMARY OF THE INVENTION

This invention includes light weight fiber-reinforced polymeric (FRP)structural building panels and panel assemblies, sized and configuredfor construction of non-portable wall structures permanently fixed tothe ground. Fiber schedule and fiber orientation in the panels provideenhanced properties of the panels. Fibers are typically oriented within15 degrees of a top-to-bottom, e.g. axial, direction in the panelproviding, in part, enhanced top-to-bottom crush strength of apanel/wall. Panels of the invention typically have a bias to deflecttoward the surface of the panel which faces outwardly of the building,toward the backfill soil which faces the panel, outside the building.Panels of the invention, having mass of no more than 18 pounds per footheight per linear foot length of the building panel, have vertical crushresistance capacity of at least 2000 pounds per linear foot length ofthe building panel, using a safety factor of 3.

In a first family of embodiments, the invention comprehends afiber-reinforced polymeric load-bearing building panel having a length,a top and a bottom, and comprising an outer fiber-reinforced polymericlayer about 0.10 inch thick to about 0.30 inch thick, the outer layercomprising a first set of continuous fibers in a first reaction-curedresin composition, the outer layer defining a first outermost surface ofthe building panel; an inner fiber-reinforced polymeric layer about 0.10inch thick to about 0.30 inch thick, the inner layer comprising a secondset of continuous fibers in a second reaction-cured resin composition,the inner layer defining a second outermost surface of the buildingpanel; and a plurality of load-bearing studs, spaced along the length ofthe building panel and extending, from the inner layer, away from thesecond outermost surface to end panels of the studs, including away fromthe building panel, the studs extending along the height of the buildingpanel, and having walls, defining outer surfaces of the studs, about0.10 inch thick to about 0.30 inch thick, the walls of the studscomprising a third set of continuous fibers in a third reaction-curedresin composition, the building panel having a thickness between theinner layer and the outer layer, excluding any dimensions of the studs,of about 2 inches to about 5 inches, the building panel having a mass ofno more than 18 pounds per foot of height per linear foot length of thebuilding panel, and a vertical crush resistance capacity of at least2000 pounds per linear foot length of the building panel when testedaccording to ASTM E72, and using a safety factor of 3.

In some embodiments, the building panel has a bending resistancecapacity, when subjected to uniform loading in accord with ASTM E72, ofup to about 250 pounds per square foot surface area of the outer layer,of no more than L/240.

In some embodiments, the building panel has a bending resistancecapacity, when subjected to uniform loading in accord with ASTM E72, ofup to about 325 pounds per square foot surface area of the outer layer,of no more than L/180.

In some embodiments, the building panel has a horizontally-directedbending resistance capacity, when subjected to uniform loading in accordwith ASTM E72, of up to about 400 pounds per square foot surface area ofsaid outer layer, of no more than L/120.

In some embodiments, the building panel has a vertical, top-to-bottomapplicable crush resistance capacity of at least 4000 pounds, optionallyat least 6000 pounds, optionally at least 8000 pounds per linear footlength of such building panel, using a safety factor of 3.

In some embodiments, the building panel, under a top-to-bottom loaddistributed between the outer layer and the end panels of the studsaccording to ASTM E72, deflects toward the outer layer.

In some embodiments, the building panel, under a top-to-bottom load,distributed between the outer layer and the end panels of the studsaccording to ASTM E72, deflects toward the outer layer, and has ahorizontally-directed bending resistance capacity, when subjected touniform transverse loading of up to about 250 pounds per square foot inaccord with ASTM E72, of no more than L/240,

In some embodiments, the building panel has a vertical crush resistancecapacity, to catastrophic panel failure, when tested in accord with ASTME72, of at least 20,000 pounds, optionally at least 25,000 pounds, perlinear foot length of the building panel.

In some embodiments, at least 50 percent by weight, of at least one ofthe first, second, and third sets of fibers, collectively, extends in adirection within 15 degrees of the top-to-bottom height of the buildingpanel.

In some embodiments, at least about 70 percent by weight, of each of thefirst, second, and third sets of fibers extends in a direction within 15degrees of the top-to-bottom height of the building panel.

In some embodiments, at least 50 percent by weight of each of the first,second, and third sets of fibers extends in a direction which issubstantially aligned with, thus parallel to, the top-to-bottom heightof the building panel.

In some embodiments, the invention comprehends an upright outer wall ina building comprising one or more building panels of the invention.

In some embodiments, the invention comprehends a building having anouter wall of the invention, as a foundation wall exposed to soilbackfill loading, and an overlying building structure bearing down onsuch foundation wall, wherein horizontal deflection of such foundationwall, when under such building load, is directed outwardly toward thesoil backfill and is limited to no more than L/120 where such overlyingload is no more than 5000 pounds per linear foot of such foundationwall.

In a second family of embodiments, the invention comprehends afiber-reinforced polymeric load-bearing building panel having a length,a top and a bottom, and comprising an outer fiber-reinforced polymericlayer about 0.10 inch thick to about 0.30 inch thick, the outer layercomprising a first set of continuous fibers in a first reaction-curedresin composition, the outer layer defining a first outermost surface ofthe building panel; an inner fiber-reinforced polymeric layer about 0.10inch thick to about 0.30 inch thick, the inner layer comprising a secondset of continuous fibers in a second reaction-cured resin composition,the inner layer defining a second outermost surface of the buildingpanel; and a plurality of load-bearing studs, spaced along the length ofthe building panel and extending, from the inner layer, away from thesecond outermost surface to end panels of the studs, including away fromthe building panel, the studs extending along the height of the buildingpanel, and having walls, defining outer surfaces of the studs, about0.10 inch thick to about 0.30 inch thick, the walls of the studscomprising a third set of continuous fibers in a third reaction-curedresin composition, the building panel having a thickness between theinner layer and the outer layer, excluding any dimensions of the studs,of about 2 inches to about 5 inches, the building panel having a mass ofno more than 18 pounds per foot of height per linear foot length of thebuilding panel, and wherein the building panel, under a top-to-bottomload distributed between the outer layer and the end panels of the studsaccording to ASTM E72, deflects between the top of the building paneland the bottom of the building panel, toward the outer layer.

In some embodiments, the deflection of the building panel is no morethan L/120 when tested in accord with ASTM E72 at an absolute loading of15,000 pounds per linear foot length of the building panel.

In some embodiments, the invention comprehends a building having anouter wall of the invention as a foundation wall exposed to soilbackfill loading, and an overlying building structure bearing down onthe foundation wall, wherein horizontal deflection of the foundationwall, when under such building load, is directed outwardly toward thesoil backfill and is limited to no more than the equivalent of L/120when no external resistance is applied, and where such overlying load isno more than 5000 pounds per linear foot of the foundation wall.

In a third family of embodiments, the invention comprehends afiber-reinforced polymeric load-bearing building panel having a length,a top and a bottom, and comprising an outer fiber-reinforced polymericlayer about 0.10 inch thick to about 0.30 inch thick, the outer layercomprising a first set of continuous fibers in a first reaction-curedresin composition, the outer layer defining a first outermost surface ofthe building panel; an inner fiber-reinforced polymeric layer about 0.10inch thick to about 0.30 inch thick, the inner layer comprising a secondset of continuous fibers in a second reaction-cured resin composition,the inner layer defining a second outermost surface of the buildingpanel; and a plurality of fiber-reinforced polymeric load-bearing studscomprising a third set of continuous fibers in a third reaction-curedresin composition, the studs being spaced along the length of thebuilding panel and extending away from the building panel, includingaway from the second outermost surface; and at least about 50 percent byweight, of at least one of the first, second, and third sets of fibers,collectively, extending in a direction within 15 degrees of thetop-to-bottom height of the building panel.

In some embodiments, at least 50 percent by weight of each of the first,second, and third sets of fibers extend in a direction within 15 degreesof the top-to-bottom height of the building panel.

In some embodiments, the building panel has a mass of no more than 18pounds per linear foot length of the building panel per foot height ofsuch one-foot length.

BRIEF DESCRIPTION OF THE DRAWINGS

FIG. 1 shows a representative pictorial view, with parts removed, of abuilding foundation wall fabricated using elements, and building systemstructures, of the invention.

FIG. 2 is a fragmented interior view of a section of one of theupstanding wall structures shown in FIG. 1.

FIG. 3 is an elevation-view cross-section of the upstanding wallstructure taken at 3-3 of FIG. 1.

FIG. 4 is an outside elevation representation of the upstanding wallstructure of FIG. 3.

FIG. 5 is a plan-view cross-section of a portion of a foundation wall ofthe invention.

FIG. 6 is an enlarged plan-view cross-section of a portion of thefoundation wall structure of FIG. 5.

FIG. 7 is an elevation view cross-section of the foundation wallstructure illustrated in FIGS. 5 and 6.

FIG. 7A shows an enlarged elevation view of a top portion of a wallsection illustrating a resin-fiber composite top cap, and a top plate,collectively being used in anchoring the overlying building structure tothe underlying wall structure at the top of the underlying wall.

FIG. 7B shows an enlarged elevation view cross-section as in FIG. 7,illustrating an anchor bracket, and a top plate, collectively being usedin anchoring the overlying building structure to the underlying wallstructure.

FIG. 7C shows an enlarged elevation view as in FIG. 7A, illustrating analternative embodiment of the top cap.

FIG. 8 is a pictorial line rendering of a resin-fiber composite supportbracket, which may be mounted to the top of a foundation wall of theinvention, and used for positioning other building structure relative tothe wall.

FIG. 9 is a pictorial line rendering of a channel stud which can beincorporated into a building panel of the invention as illustrated ine.g. FIGS. 5-7.

FIGS. 10A and 10B are pictorial line renderings of second and thirdembodiments of studs which can be incorporated into building panels ofthe invention.

FIG. 11 is a pictorial line rendering of a resin-fiber composite “H”connector which is used to connect first and second building panels/wallsections to each other where the wall extends along a straight path.

FIGS. 12 and 13 are pictorial line renderings of resin-fiber compositeangle brackets which can be used on inner and/or outer surfaces of awall section, connecting first and second wall sections to each other atselected angles.

FIGS. 14 and 14A are pictorial views of exemplary right-angle plateanchor brackets useful at the tops and bottoms of building panels of theinvention e.g. for securing the panels to underlying structure andsecuring overlying and/or weight-bearing or weight-transferringstructures to the building panel.

FIG. 15 shows a plan view cross-section of an embodiment of buildingpanels of the invention wherein channel studs are between the innerlayer and foam blocks.

FIG. 16 shows a plan view cross-section of a wall section using studswhich extend to the outer layer.

FIG. 17 shows a plan view cross-section of an upstanding building panelwhere foam blocks, between the inner and outer layers, are wrapped inlayers of fiber.

FIG. 18 shows a cross-section as in FIG. 17, illustrating a ribbed outerlayer.

FIG. 19 illustrates a fragmentary end elevation view of a building panelpre-form in a vacuum bag molding process being used to fabricate abuilding panel with foam blocks, wrapped in fiber as in FIG. 17, and aninner layer overlying the studs as illustrated in FIG. 15.

FIG. 20 shows a plan view cross-section of another embodiment of anupstanding building panel of the invention wherein fiber layers, wrappedabout foam blocks, provide the reinforcement structure of thereinforcing members as well as stud reinforcement

FIG. 21 shows a plan view cross-section of another embodiment ofupstanding building panels.

FIG. 22 shows a cross-section of a building panel incorporatingrectangular studs as in FIG. 10B.

FIG. 23 illustrates, in line representation, vacuum infusion apparatusfor making a building panel of the invention, which building panel hasstuds extending from the inner surface thereof.

FIG. 24 shows a cross-section of a building panel incorporatingfiber-wrapped foam blocks as studs.

FIG. 25 shows an end view of a top portion of the panel of FIG. 24.

FIG. 26 shows a cross-section of a building panel wherein fiber-wrappedfoam blocks are disposed between the inner and outer layers, wherein thesecond outermost layer overlies the studs, wherein reinforcement layersare added over the otherwise first and second outermost layers.

FIG. 27 shows a cross-section of a building panel of the inventionhaving no intercostals, a first reinforcement layer over the otherwisefirst outermost layer, a second reinforcement layer between the foampanel and the second outermost layer, the second outermost layeroverlying the studs and the second reinforcement layer.

FIG. 28 shows an enlarged plan-view cross-section of a portion ofanother embodiment of wall structure of the invention.

FIG. 29 is a further enlarged cross-section view of a portion of thewall structure of FIG. 28, showing additional detail.

FIG. 30 shows a plan view of a foam-filled panel having studs but, likeFIG. 27, having no reinforcing intercostals.

FIG. 31 is an elevation view cross-section of a foundation wallstructure of the invention showing a hollow concrete block as a minifooter.

FIG. 32 is an elevation view as in FIG. 31, showing a solid pouredconcrete mini footer, with steel reinforcing rods extending through themini footer.

FIG. 33 is a side elevation view of a lower portion of the foundationwall of FIG. 32, with the top of the floor/footer shown in dashedoutline.

FIG. 34 is a top view of a straight portion of a wall structure,illustrating use of a mini footer at a joint in the wall.

FIG. 35 is a top view of a corner portion of a wall structure,illustrating use of a mini footer in a corner wall structure.

FIG. 36 is a top view of a straight wall section, intersected by anabutting wall.

FIGS. 37 and 38 illustrate studs which include top and bottom mountingflanges.

FIG. 39 shows a fragmented elevation view cross-section of a wallstructure showing securement of the flanged studs to underlying andoverlying structure.

FIGS. 40 and 41 illustrate an FRP brace cap which extends the length ofthe lower sill of a window rough opening, thus adapting the wall toreceive the side load of backfill which can extend up to near the lowersill of the window.

FIG. 42 shows one or more dimension lumber studs laid flat under thewindow opening to stiffen the lower sill.

FIG. 43 is a pictorial view showing multiple mini footers in place,along with reinforcing steel in the mini footers, at locations whichwill be occupied by the monolithic footer/floor slab combination laterin the construction project.

FIG. 44 shows a pictorial view of part of the footer location shown inFIG. 43, with a building panel placed on one of the mini footers.

The invention is not limited in its application to the details ofconstruction, or to the arrangement of the components set forth in thefollowing description or illustrated in the drawings. The invention iscapable of other embodiments or of being practiced or carried out invarious other ways. Also, it is to be understood that the terminologyand phraseology employed herein is for purpose of description andillustration and should not be regarded as limiting. Like referencenumerals are used to indicate like components.

DETAILED DESCRIPTION OF THE ILLUSTRATED EMBODIMENTS

Referring to FIG. 1, a plurality of interior and exterior foundationwalls 10 collectively define the foundation 12 of a building. Eachfoundation wall 10 is defined by one or more foundation building panels14. In the illustration, a foundation building panel 14 is shown toinclude a bottom plate 16, and further includes an upstanding wallsection 18, and a top plate 20. Each upstanding wall section 18 includesa main-run wall section 22, and uprightly-oriented reinforcing studs 23affixed to, or integral with, the main-run wall section, the studs beingregularly spaced along the length of the wall section, and extendinginwardly of the inner surface of the main run wall section. In theembodiment illustrated in FIG. 1, anchoring brackets 24 are mounted tothe studs at the tops and bottoms of the wall section, thus to assist inanchoring the bottom plate and the top plate, and/or any otherattachment, to the wall.

As illustrated in FIG. 1, conventional e.g. steel I-beams 26 can bemounted to the wall sections, as needed, to support spans of overlyingfloors. Such steel I-beam can be supported at one or more locationsalong the span of the I-beam, as needed, by support posts 28 and rigidfooter pads 30, which may be embedded in a concrete slab floor 38.

Referring now to FIGS. 3, 5, and 6, the main run wall section 22 of thebuilding panel is generally defined between the inner surface 25 and theouter surface 56 of the building panel, without considering that portionof the thickness of the wall which is defined by stud 23. The main runwall section of the panel thus generally includes a foam core 32, aninner fiberglass layer 34 and an outer fiberglass layer 36. Thefiberglass layers 34, 36 are fiberglass-reinforced polymer (FRP), alsoknown as polymer-impregnated fiberglass. Outer layer 36 represents afirst outermost layer of the building panel. Inner layer 34 represents asecond opposing outermost layer of the building panel. The foam core canbe foamed-in-place thermally insulating material between pre-fabricatedinner and outer layers, or can be made from pre-fabricated blocks ofthermally insulating foam material. The foam blocks are assembled withthe remaining elements of the respective building panel as described infurther detail hereinafter. Bottom plate 16 and top plate 20 can besecured to the main run wall section with the support of wedge-shapedbrackets 24 (FIGS. 2, 3, 14), or elongate angle-shaped brackets 24A(FIGS. 6, 7, 7B, 14A).

Elongate angle bracket 24A resembles a conventional angle iron and maybe a length of angle iron. For sake of material consistency, an FRPcomposition, similar to that of e.g. inner and outer layers 34, 36 maybe used in an angle bracket 24A, and has sufficient rigidity to supportthe overlying structure in a generally angularly-constant relationshipas the overlying structure is supported by the underlying buildingpanel. As used in an upright building panel 14, angle bracket 24A has avertical leg 24V and a horizontal leg 24H, the two legs 24V, 24H meetingat the apex of the angle formed by the two legs. Angle bracket 24A hasan elongate length which generally extends up to the portion of thelength of the panel which extends between adjacent studs 23. Thus, wherethe distance between adjacent studs is 14.5 inches, length of the anglebracket is typically about 8-13 inches. A plurality of holes, extendingthrough each of the legs 24V, 24H, are spaced along the length of thebracket.

At the top of the panel, bracket 24A is used to secure the overlyingbuilding structure to panel 14. Thus, one or more bolts 139 (FIG. 7)extend through the horizontal leg 24H of the bracket, through any cap orbracket which overlies the building panel, and into or through the topplate 20, thus securing the top plate to bracket 24A. Bracket 24A isshown secured to the panel by screws 139S which extend through verticalleg 24V and through inner layer 34 of the building panel. Adhesive canbe used instead of screws 139S to secure vertical leg 24V to the wallpanel.

Bottom plate 16, where used, can be a fiber-reinforced, e.g.fiberglass-reinforced, polymeric structural member, of such dimensionsas to be sufficiently rigid, and having sufficient strength, to supportboth the foundation wall and the overlying building superstructure, froman underlying fabricated base and to spread the weight of the overlyingload over the natural support base, within the weight-bearing limits ofthe natural support base. Such fabricated base can be e.g. a settled bed53 (FIG. 7) of stone aggregate, a conventional concrete footer 55 (FIG.3), or other suitable underlying fabricated supporting base. Thespecific structural requirements of bottom plate 16, as well as thefooter, depend on the loads to be applied.

The bottom plate, where used, can be attached to the upstanding wallsection by brackets 24A using e.g. steel bolts or screws which extendthrough vertical leg 24V of the bracket and into and through inner layer34, and through the horizontal leg 24H and into and through the bottomplate. Adhesive can be used instead of screws or bolts to securevertical leg 24V to the wall panel. A wall system which includes abottom plate can be used without a footer. In such instance, the bottomplate is sufficiently wide, thick, dense, and rigid, to provide theeffective compression and bending support normally attributed to thefooter. Thus, whether bottom plate or footer, the structure between theload and the natural base distributes the overlying load over asufficiently wide area of the underlying base that load per unit areaexerted on the underlying base is no more than the load capacity of theunderlying base such that the underlying base can support the buildingload for an indefinite period of time without the building load causingany substantial vertical or lateral movement of the underlying base.Where a footer is used in combination with the bottom plate, the bottomplate need not have as large an area because the footer takes over thefunction of load distribution to the underlying e.g. soil or rock base.

The bottom plate typically extends laterally inwardly into the buildingbeyond the primary surface 25 of inner layer 34 at the main run wallsection, and may extend by a distance corresponding to at least thethickness of the building panel which includes studs 23, whereby thearea of the bearing surface presented to the footer or the underlyingsupport base where no footer is used, including the load presented bystuds 23, distributes the overlying load at least over the area of thefootprint of the wall as well as over the area represented by thecavities between studs 23.

The top plate is sufficiently wide, thick, and rigid to provide asupport surface, interfacing with the underlying upstanding wallsection, and distributes the load of the overlying building structure,at least regionally, along the length of the wall. The top plate canconveniently be made from fiber-reinforced polymeric material, or fromconventional dimension wood lumber whereby overlying building structurescan be conventionally attached to the underlying foundation wallstructure at the building site by use of conventional fasteners such asscrews or bolts, conventionally attached to the top plate.

Referring to FIGS. 1, 3, and 7, once the foundation wall 10 is in placeas illustrated in FIG. 1, on a suitable footer (e.g. 53, 55), aconventional ready-mix concrete slab floor 38 can be poured. Theconcrete slab floor extends over, and thus overlies, that portion of anybottom plate 16 which may underlie the foundation wall, and extendsinwardly from any of the inner surfaces of the building panels,including both the inner surfaces of the main run wall section and theinner surfaces of studs 23. Namely, the concrete slab floor extends to,and abuts against, the inner surfaces of the respective upstanding wallsections 18 at inner layers 34 and at studs 23. Accordingly, once theconcrete slab floor is cured, inwardly-directed lateral forces, imposedby the ground outside the building, at the bottom of the wall, areabsorbed by the structural e.g. lateral compressive strength of theconcrete floor slab 38 in support of foundation wall 10, as the edge ofthe slab abuts the inner surface of the foundation wall.

Inwardly-directed lateral forces which are imposed on the foundationwall at or adjacent top plate 20 are transferred to main floor 40 of thebuilding (FIGS. 3, 7) e.g. through angle bracket 24, 24A and/or bolts139 or screws. In the embodiments illustrated in e.g. FIGS. 3 and 7, theforce passes from the wall to the top plate, from the top plate to thefloor joists or trusses, with some of the force potentially transferringinto the sub-flooring and/or finished flooring.

Still referring to the main run wall section 22 (FIGS. 1, 3, and 6), andconsidering the structural environment of typical 1-story and 2-storyresidential construction, inner layer 34 and outer layer 36 are e.g.between about 2.5 mm and about 7.6 mm (between about 0.1 inch and about0.30 inch) thick. Typical thicknesses of the inner and outer layers areabout 0.15 inches to about 0.25 inches, optionally about 0.13 inches toabout 0.16 inches. Thickness of the inner 34 is typically about 0.15inch to about 0.19 inch, while thickness of outer layer 36 is typicallyabout 0.19 inch to about 0.25 inch. Thicknesses of each of layers 34, 36are generally constant.

FIG. 18 shows the outermost layer of panel 14 includingupwardly-extending ribs 191 which enhance the lateral bending resistancecapacity of the wall, thus the ability to withstand the imposition oflaterally-directed loads on the wall. Inner layer 34 can be providedwith similar ribs 191 to provide even more lateral loading strength.Ribs 191 typically are additive to the nominal thickness of layer 34 or36, and add e.g. about 0.5 mm to about 2 mm to the overall thickness ofthe respective layer at the rib location. In the alternative, therespective layer 34 or 36 can have recesses on its inner surface,opposite ribs 191 of the outer surface of the respective layer wherebythe layer generally maintains its nominal thickness at ribs 191.

In the embodiments illustrated in FIGS. 1-6, studs 23 run the fullheight of the main run wall section, and extend from inner layer 34inwardly, and away from outer layer 36, a desired distance so as toprovide the desired level of structural strength to building panel 14,as well as to provide a desired depth to channels 131 between end panels44 of the studs and surface 25 of inner layer 34.

In the embodiments illustrated in FIGS. 15-16, inner fiberglass layer 34is wrapped around end panels 44 of the studs. The wrapping of thefiberglass layer over the studs as illustrated in e.g. FIG. 16incorporates the stud into the unity of the structure of the main runwall section, whereby additional bending resistance strength of the studin resisting a lateral force is added to the bending resistance of theinner layer, which significantly enhances the overall bending resistancestrength of the wall section. Thus, one function of studs 23 is theirservice as reinforcing elements in building panel 14.

Studs 23 can be conventional wood e.g. 2×4 or 2×6 studs, or can be madeby wrapping one or more e.g. concentric layers of e.g. resin-impregnatedfiberglass sheet on itself until the desired cross-sectional shape isobtained, and impregnating the fiberglass layers with a curable resin.As other illustrative embodiments, studs can be fiber-reinforcedpolymeric structures or conventionally-available elongate steel studprofiles known in the trade as “steel studs”. As fiber-reinforcedstructures, there can be mentioned 3-sided rectangular-shape structuresas in FIGS. 6 and 17, or 4-sided dosed rectangular structures as in FIG.26. The studs can be hollow as in FIGS. 6 and 17, or can be filled withthermally-insulating foam as in FIG. 28. In the alternative, the studcan be made by wrapping one or more fiber layers around a foammandrel/core. Steel studs can be shaped, for example and withoutlimitation, as C-shape, H-shape, I-shape, dosed rectangle, or otherknown or novel profiles.

The stud can be mounted to the panel at inner layer 34 as illustrated inFIGS. 6 and 17, or to an intermediate layer adjacent inner layer 34 asillustrated in FIG. 27, or can be mounted to outer layer 36 and extendthrough the panel to, and past, inner layer 34 as in FIG. 16. All suchstuds provide an elongate structural profile extending along the heightof the panel, and which elongate structural profile provides desiredstructural and spatial properties.

Referring to FIGS. 1-4, in general, the inner and outer layers of thewall section are illustrated as fiberglass-reinforced resin layers, fullheight and full length of the wall section. The inner and outer layers34, 36 are e.g. about 2.5 mm to about 6.3 mm thick, optionally about 3.8mm to about 6.4 mm thick. The foam between layers 34, 36 is represented,in such embodiments, by unitary blocks of foam which extend the fullheight of the panel and fill the entirety of the space between the innerand outer layers 34, 36, except where studs 23 or reinforcement members50 fill space between the inner and outer layers; with foam filling allother space between layers 34 and 36.

Any top plate or bottom plate can be made from conventional e.g. woodmaterials, with suitable waterproofing as appropriate for the intendeduse. Such wood can be treated to inhibit growth of wood-consumingorganisms. In order to avoid issues of potential deterioration of thewood as a result of the wood contacting moisture, typically the bottomplate, when used, is a fiberglass-reinforced resinous composite, forexample a pultruded plate, of sufficient thickness, width, and rigidityto provide the level of weight bearing capacity, and weight-distributionrigidity, anticipated as being appropriate, for supporting the overlyingstructure to be supported. However, in some embodiments, the bottom ofthe wall structure is placed directly on the footer, whereby no bottomplate is used.

As used herein, all fiberglass/resin composite structures, such as innerlayer 34, outer layer 36, bottom plate 16, top plate 20, studs 23, andthe like, can be fabricated using known techniques of dry orpre-impregnated fiberglass blanket manipulation and construction,including resin impregnation of such materials, chop spray processes,vacuum infusion processes, pultrusion, open mold wet lay-up process, orother processes known for making fiber-reinforced composites, in orderto make the desired 3-dimensional shapes. Such techniques can be used,for example, to make building panel 14, bottom plate 16, top plate 20,studs 23, brackets 24, 24A, 140, 148, 170, and the like.

Structural building panels of the invention can be manufactured in anystandard dimensional sizes, as well as in custom size combinationsdesired for a particular building project. Thus, for example and withoutlimitation, such panels can have heights of about 3 feet to about 5feet, typically about 4 feet, which accommodates use of the panels infrost walls and crawl spaces; or height of about 8 feet to about 10feet, typically about 9 feet which accommodates use of the panels instandard-height basement walls and standard-height above-grade walls.

Wall section thickness “T” (FIG. 6), and thus the panel thickness, inthe main-run wall section is defined without respect to the dimensionsof studs 23, and generally stops at the surface 25 of what is laterdefined herein as space 131 between the studs 23. Thickness “T” can beas little as about 2 inches between the inner and outer surfaces of thewall, to as much as about 8 inches or more, as measured between theouter surface 25 of layer 34 and the outer surface 56 of layer 36. Wallthickness “T” is more typically about 3 inches to about 6 inches, moretypically about 3 inches to about 5 inches.

Studs 23 can extend inwardly from such nominal dimensions. Such studdepth is typically at least 3 inches. Such typical stud depth assists inproviding desired bending resistance and vertical crush resistance, aswell as in providing desired thermal insulation properties, and may beinstrumental in urging the wall to flex outwardly, against the lateralsoil load when loaded with a downwardly-directed overlying load.Additional bending resistance can be obtained through the use of studswhich have even greater depths, or greater width, inward from the innerlayer. Further, additional thermal insulation properties can be obtainedby adding conventional insulation material 135 between studs 23 at theinner surface of the panel as illustrated in FIG. 15.

Typically, thickness “T” greater than 8 inches is not needed in order tosatisfy structural demands or thermal insulation demands of a typicallow-population-density residential building. However, in some instances,where additional thermal or structural demands are to be imposed on thebuilding panels, then thickness greater than 8 inches is contemplated.

Length of a panel 14 is limited only by transportation capabilities. Forexample, such panel can be as long as the length of the truck bed whichwill transport the panel to the construction site. Thus, length isgenerally limited to about 40 feet, but can be shorter as suggested by aparticular construction project requirement, or longer where suitabletransport is available. Relatively longer panels can be cut for length.Typical lengths of the panel, as contemplated to be manufactured in massproduction, are between about 6 feet and about 40 feet, and wheretransportation is not a limitation, up to about 50 feet, up to about 60feet, up to about 70 feet, or up to about 80 feet, and all lengthincrements between about 6 feet and about 80 feet. However, since anadvantage of the panels is limited weight such that the panels can beinstalled below grade and at grade level with use of only a light-dutycrane, length is in some embodiments limited to lengths which canreadily be handled by such light duty crane.

In the case of highly segmented walls, relatively shorter wall segmentscan be desired whereby the lengths of the panels may be relativelyshorter. Thus, panels as short as about 4 feet, about 6 feet, about 8feet, about 10 feet, about 15 feet, about 20 feet, and about 25 feet arecontemplated, still with minimum of 3-5 feet in height, and optionallyabout 8-10 feet in height, in order to perform either as a frost wall oras a full-height first story, e.g. foundation, wall.

The structural building panels of the invention provide a number ofadvantages. For example, the panels can be manufactured in a continuouslength, and cut to any desired length for shipping, which may be ageneric length, for example 10 feet, or 20 feet, or 40 feet, or whateverlength or lengths is or are desired. The length needed for a particularportion of a building wall can be cut from a generic-length buildingpanel, at the construction site, to meet specific needs, or can be cutto specific length at the panel manufacturing site, or at situs of afabricator or other distributor. Thus, if a shorter length is needed fora particular portion of the wall, the needed length can be cut from e.g.a 40-foot long section. If a longer length piece is needed, either alonger length panel can be fabricated as a unitary product at thepanel-manufacturing facility, or two or more pieces can be joinedtogether using suitable straight-run connectors, or corner connectors,as suitable for the particular assembly to be made. The respectivebuilding panels can be cut to length, using e.g. a circular saw, a ringsaw, or a reciprocating saw, employing e.g. a masonry blade, andassembled to each other at the construction site.

Because the wall assembly is made primarily from fiber, resin, and foam,the pounds per cubic foot density, and thus the unit weight per foot oflength of the wall assembly is relatively small compared to a concretewall of corresponding dimensions. For example, a building panel 20 feetin length, 9 feet in height, and having a main run wall section which isnominally 3 inches thick, weighs about 1100 pounds, including studs 23,namely about 55 pounds per foot length of the panel, and 6.1 pounds unitmass for each foot of height of such one-foot length. Accordingly, atypical foundation for an average single-family residence in the US,using the invention, is about 160 feet in length and weights a total ofabout 7200 pounds/3265 kg whereas a concrete foundation for the samehouse weighs about 150,000 pounds/68,000 kg.

The invention contemplates a range of such length/height unit mass of,for example and without limitation, about 2 to about 18 pounds per footof height per linear foot length of said building panel, and allincremental masses in between.

Rough openings for windows 27 and/or doors 29, illustrated in FIG. 1,can be cut on site using the above-noted masonry blade. Accessories, andother connections between elements of the wall and between the wall andother building elements, can be mounted to the wall by drilling andbolting conventional building construction elements to the buildingpanel, or by use of self-tapping fasteners driven into the buildingpanel, or by using known construction adhesives and resins formulatedfor use with fiber-reinforced polymeric materials. Screws or bolt-nutcombinations can be used for typical attachments and connections wherebythe screws and/or bolts facilitate or enable transfer of the fulloverlying portion of the building load from an overlying building memberto an e.g. underlying foundation wall which uses building panels of theinvention. Where screws are suitable for use as connectors/fasteners,known construction adhesives and resins can be used as alternative.

FIGS. 5-7 represent one embodiment of wall structures, and walls, of theinvention, which have a reinforcing structure extending across thethickness of the building panel. FIG. 5 represents a top view of aportion of a foundation wall section, including a 90 degree corner inthe foundation wall. FIG. 6 is an enlarged cross-section, in plan view,of a straight-run portion of the foundation wall shown in FIG. 5. FIG. 7is a cross-section, in elevation view, of a portion of the foundationwall shown in FIGS. 5 and 6.

FIGS. 5-6 show that a substantial portion of the volume of thefoundation wall is occupied by a series of blocks 32 of low-densitythermally insulating foam. As in the embodiments of FIGS. 1-4, inner 34and outer 36 layers of fiberglass-reinforced resin form the genericinner and outer layers of the building panels 14.

As best seen in FIG. 6, a first reinforcing function is provided by acontinuous, reinforcing, intercostal weaving layer 50. Weaving layer 50weaves back and forth from one of the inner 34 and outer 36 layers tothe other of the inner and outer layers. The back and forth weaving pathis disposed between each of the foam blocks 32, namely at spacedcrossing locations, spaced along the length of the building panel wherethe intercostal layer 50 is perpendicular to the inner and outer layers.Such crossings are typically spaced from each other, along the length ofthe building panel, by about 4 inches to about 24 inches, typically byabout 6 inches to about 12 inches. More typically, the foam blocks areabout 8 inches wide such that the crossings are spaced about 8 inchesfrom each other. As with the inner and outer layers, for conventionalresidential single-family construction, the weaving layer, at thecrossing locations, has a nominal thickness of about 0.10 inch (2.5 mm)thick to about 0.30 inch (7.6 mm) thick.

Thus, referring to FIG. 6, weaving layer 50 extends from left to rightalong the inner surface 42 of outer fiberglass layer 36, between layer36 and a foam block 32A to the side of the width “W” of foam block 32A.Still referring to FIG. 6, at the right side of foam block 32A, weavinglayer 50 turns a 90 degree angle and extends to the inner surface 52 ofinner fiberglass layer 34. At the inner surface 52 of inner fiberglasslayer 34, the weaving layer makes another 90 degree turn, and extends tothe right along inner surface 52 of the inner fiberglass layer along thefull width of foam block 32B, then turns and again goes back to theinner surface of outer fiberglass layer 36. Weaving layer 50 thusfollows a back and forth path between inner 42, 52 surfaces of inner andouter layers 34, 36, along the entire length of the respective buildingpanel 14 whereby layer 50 is in contact with one of layers 34, 36 oversubstantially the entirety of the length of the panel. Layer 50 is ingenerally complete surface-to-surface contact with the respective layers34 and 36, and with the respective foam blocks 32, along the entirety,or substantially the entirety of its path and along substantially allportions of the respective facing surfaces where layer 50 faces layers34 and 36, and foam blocks 32.

The respective layers 34, 36, 50, and foam blocks 32, are all integrallybonded to each other to make a unitary composite structural product.Thus, the weaving layer is attached to respective elements of both theinner and outer layers, whereby the thicknesses of the inner and outerlayers, as combined with the weaving layer, vary between relativelysubstantially thicker portions and relatively substantially thinnerportions, each of which occupies about half of the length of each of theinner and outer layers. Typically, the relatively thicker portions ofthe combined layers 34, 50 and 36, 50 are at least 50 percent thickerthan the relatively thinner portions of the layers 34 and 36. Theresultant composite product functions much like an I-beam where layers34 and 36, and combined elements of layer 50, serve as flange elementsof an I-beam-like structure, and the crossing portions of weaving layer50, function as web elements of such I-beam-like structures.

In general, all the space between inner surface 57 of the main runportion of the building panel and outer surface 56 of the panel isoccupied by layers 34, 36, and 50, and the foam blocks, whereby little,if any, of the space between layers 34 and 36 is not occupied by any ofthe above-recited panel materials. By so generally filling the spacebetween layers 34, 36, and reinforcing the panel using the crossingintercostal webs 50, all of the panel members are fixed in theirpositions relative to each other, and the panel is generallydimensionally stable under designed loading conditions, wherebyespecially laterally-directed loads imposed on the panel, from outsidethe building, whether subterranean ground loads or above-grade e.g. windloads, are efficiently transferred from outer layer 36 and distributedamong the other members of the panel, and respective portions of layers34, 36, and 50, and studs 23, share in the support of any one e.g.vertically-directed or horizontally-directed load. The resulting panelis stiff, rigid, and sufficiently strong to support all loadsanticipated for e.g. a low-population-density residential dwelling,including severe weather loads to which the building is expected to betypically subjected under normal use environments, including normalseasonal environmental extremes in the geographical location where thepanel is expected to be used.

FIGS. 5, 6, 7, 9, and 15 illustrate elongate fiber-reinforced polymericchannel studs 23. A respective such channel stud 23 is a unitarystructure which has first and second flanges 126 interfacing with theouter surface of inner layer 34. Flanges 126 are bonded to inner layer34 either through the resin which forms part of layer 34, or through aseparate adhesive or resin layer, or by mechanical fasteners such asscrews. First and second upstanding legs 128 extend from flanges 126 toan end panel 44. End panel 44 forms that surface of the stud whichextends to the greatest extent into the interior of the building, andaway from the outermost surface 25, of the panel, which faces into thebuilding. In the panel assembly, a hollow space 133 is defined inside arespective stud 23. Hollow space 133 is enclosed by the combination ofend panel 44, legs 128, and inner layer 34.

Flanges 126, legs 128, and end panel 44 generally form a unitarystructure. The structure of channel stud 23 can be relatively thin, forexample end panel 44, legs 128, and flanges 126 can be about 2.5 mm toabout 7.6 mm thick. The overall thickness of the stud, between outersurfaces of legs 128, is about 0.25 inch to about 15 inches, typicallyabout 1 inch to about 3 inches, optionally about 1.5 inches. Typically,end panel 44 is displaced from the flanges and the inner layer by about1 inch to about 5.5 inches, optionally about 2 inches to about 4 inches.Even in the recited such thin cross-section, in light of the distancebetween the end panel and the flanges, and given a maximum fiberglassloading in the stud, stud 23 makes a substantial contribution to theability of the panel to resist lateral, e.g. bending, forces imposed byground forces, or wind forces, from outside the building.

FIG. 10A shows a second embodiment of studs 23. In the embodiments ofFIG. 10A, the two outwardly-disposed flanges 126 are replaced with asingle bridging flange 126 which connects the legs 128 to each other,whereby a stud 23 of FIG. 10A represents an elongated enclosedsquare-cross-section body, encompassing hollow space 133, and open atopposing ends of the stud. The studs 23 of FIG. 10A can be usedgenerally any place the studs of FIG. 9 can be used. For example, suchstuds can be joined to the panel assembly at the outer surface of innerlayer 34. For example, the studs of FIG. 10A can be joined to the foamblocks, and inner layer 34 can be applied over the studs. In thealternative, studs 10A can be adhesively mounted, such as with a curableliquid resin or a conventional construction adhesive, to the outersurface of inner layer 34.

FIG. 10B shows a third embodiment of studs 23. As in the embodiments ofFIGS. 9 and 10A, studs 23 of FIG. 10B can be made by impregnating afiberglass matt with resin, and curing the resin. In the embodiments ofFIG. 10B, the two outwardly-disposed flanges 126 are replaced with asingle bridging flange 126 as in the embodiments of FIG. 10A, and thedepths of legs 128 are extended, compared to the legs shown in FIGS. 9and 10A. Namely, legs 128 in the embodiments of FIG. 10B are long enoughthat the stud can be mounted in the panel assembly at or adjacent outerlayer 36. FIGS. 16 and 22 illustrate hollow fiber-reinforced polymericstuds 23 of FIG. 10B assembled into building panels of the invention.

Panels of the invention can be joined to each other using any of avariety of joinder structures known in the art such as “H” brackets, “L”brackets, and more complex-shape brackets. Such joining of the wallpanels to each other can be supplemented by driving screws through suchbrackets and into and through inner and outer layers 34, 36 of therespective panels.

FIG. 5 illustrates joining together of two building panels 14A and 14Cusing first and second corner brackets 148 of FIG. 12. Each cornerbracket has first and second flanges 152 which meet at a 90 degree angleat a respective corner 154.

FIG. 13 illustrates a variable-angle bracket 170 which has two rigidflanges 152, and a flexible hinge area 172, joining the two panels 152,and which can be flexed to any included angle of from about 15 degreesto about 175 degrees. Bracket 170 is used to join together buildingpanels at joints where the panels 14 are neither perpendicular to eachother nor aligned with each other. After rigid flanges 152 have beenbonded to surfaces of the building panels 14 which are being joined, andthe building panels have been set at the desired included angle withrespect to each other, the flexible hinge area can be made rigid byapplying, to the hinge area 172, one or more coatings of the hardeningcurable 2-part resin such as is used to make building panels 14 andbracket flanges 152 of bracket 148. The same bonding, and making rigid,can also be done using well known and conventional, curing, hardeningconstruction adhesives.

FIGS. 5-7, 14, and 14A illustrate anchor brackets 24 and 24A. A bracket24 or 24A is mounted to the interior surface of inner layer 34 at thetop of the building panel. Referring to FIG. 14, top flange 136 ofbracket 24 extends transversely from, and is joined to, the top of baseflange 134. Side flange 138 extends transversely from, and is joined to,both base flange 134 and top flange 136, thus supporting top flange 136from base flange 134, and supporting base flange 134 from top flange136.

In a wall assembly, base flange 134 or side flange 138 is positionedagainst e.g. inner layer 34 of a building panel 14 and is mounted toinner layer 34 using e.g. self-tapping screws, and optionally issimilarly mounted to stud 23 at the respective corresponding side flangeor base flange. Top flange 136 interfaces with and supports top plate20, and may be mounted to the top plate by bolts or screws (FIG. 3),whereby bracket 24 serves to transfer loads between top plate 20 and themain run portion of the building panel at inner layer 34, thereby makingthe top plate an integral load-bearing element of the foundation wall.

Bracket 24 is similarly used to attach the panel to either a bottomplate, or to the footer. One of side flange 138 or base flange 134 canbe used to attach bracket 24 to stud 23, while the other of side flange138 or base flange 134 is used to attach the bracket to inner layer 34.Accordingly, bracket 24 can transfer building loads to and from bothinner layer 34 and a leg 128 of a stud 23.

Referring to FIG. 8, in bracket 48, a horizontal upper panel 182 isdesigned and adapted to extend across the top of the main run portion ofthe building panel. A keeper panel 184 extends vertically down from thedistal edge of the upper panel. A base panel 178 extends in a downwarddirection from the proximal edge of the upper panel to a lower edge ofthe base panel. A bracing panel 180 extends upwardly from the lower edgeof the base panel and away from the base panel. A support panel 176extends outwardly from a mid-portion of the base panel, and the distaledge of the bracing panel meets and supports the distal edge of thesupport panel.

FIG. 7 illustrates, in edge view, the addition of support bracket 48against the outer surface 56 of the wall, along with the interface ofangle bracket 24A with bracket 48 and top plate 20 in a channel 131. Inthe embodiment illustrated in FIG. 7, the top plate is a conventionalwood board, and is secured to bracket 24A by a bolt 139 which alsopasses through top panel 136 of bracket 48, top plate, 20, and throughthe bottom stringer of a truss which supports the overlying floor 40.FIG. 7 also illustrates a second anchor bracket 24A used in supportingthe interface between the building panel and bottom plate 16. Theattachments between bracket 24A, bottom plate 16, and inner layer 34 canalso be done by screws and optionally bolts.

FIG. 7A is another enlarged view embodiment of a top portion of anotherfoundation wall structure. In the embodiment illustrated in FIG. 7A, themain run portion 22 of the building panel contains foam blocks asindicated at 32. A given foam block is wrapped with fiberglass on theblock surface which faces outer layer 36; and on the sides of the blockswhich face each other, with the blocks arranged side-by-side between theinner and outer layers, whereby the fiberglass on the facing sides ofthe foam blocks, as combined with the resin, can form the equivalent ofreinforcing intercostal webs 50.

Still referring to FIG. 7A, a structural cap 342 covers the top of panel14, including overlying the main run wall section and overlying thestuds, and extends downwardly over both the outer face of the panel andover end panels 44 of the studs. Thus, cap 342 has a horizontal topplate 344 which overlies and contacts the top of the panel, includingthe tops of the studs. Horizontal plate 344 generally extends the fulllength of the panel, and extends from the outer surface 56 of outerlayer 36 to the exposed surfaces of end panels of studs 23. An innerflange 346 extends downwardly from the inner edge of horizontal plate344 to a first distal end 348. An outer flange 350 extends downwardlyfrom the outer edge of horizontal plate 344 to a second distal end 352.

Cap 342 is made of a rigid durable material such as a fiberglassreinforced polymeric structure. An exemplary such cap is a pultrudedstructure using the same material as disclosed for inner and outerlayers 34, 36, but optionally thicker than the inner or outer layer,namely about 0.18 inch to about 0.50 inch thick. Other materials havingsimilar physical properties are also contemplated as being acceptablefor use in/as cap 342. More robust specifications are contemplated formore demanding implementations of the invention.

Cap 342 is affixed to building panel 14. A wide variety of methods canbe used for such affixation. For example, the cap can be adhered to thebuilding panel at the respective interfacing surfaces of layer 36 andend panels 44 using conventionally available construction adhesive orcurable resin. In the alternative, screws 366 or other mechanicalfasteners can be applied spaced along the length of the building panel,e.g. through inner flange 346 and into end panels 44 of the studs, andthrough outer flange 350 and into the main run wall section at layer 36,thus to anchor cap 342 to the underlying building panel.

Holes can be e.g. drilled in cap 342, and end panels 44, to facilitatedriving the screws or other fasteners through the cap and into therespective other members of the corresponding elements of the construct.

In the embodiment illustrated in FIG. 7A, top plate 20 overlies cap 342.Top plate 20 spreads the load of the overlying floor 40 and otherstructure over the full width of horizontal plate 344 of cap 342.

Still referring to FIG. 7A, rim joist 354 overlies and bears on topplate 20, and extends along the length of top plate 20, cap 342, andthus along the length of the respective wall. Rim joist 354 is affixedto top plate 20 by a plurality of nails or screws 360 which are spacedalong the length of the plate and rim joist. A plurality of floor joistsor floor trusses 356 are spaced along the length of top plate 20, andthus along the length of rim joist 354, and extend transversely from rimjoist 354 into and/or across the building, thus to provide support forthe overlying floor 40.

Conventional wall plate 358 overlies floor 40 and is screwed or nailedinto the floor joists and the rim joist by a plurality of screws ornails. Wall plate 358 and its overlying structure, shown only in nominalpart, represent the overlying walls which, along with all other buildingstructure, enclose the respective floor/story of the building and bearthe associated loads which ultimately bear on the foundation wallthrough floor 40, joists or trusses 356, rim joist 354, top plate 20,seal 357 (FIG. 7B), and ultimately cap 342.

Where the building panels do not include studs, top plate 20 and/orbottom plate 16 or footer 55 can extend inwardly of inner surface 25 adistance sufficient to overlie, or underlie respectively, the top flange136 of brackets 24, 24A mounted to inner layer 34, such that brackets24, 24A can still be used to tie the panels to the bottom plate orfooter, and/or to tie the overlying structure to the panels.

A plurality of anchor screws 362 extend upwardly in the utility runcavities/spaces 131 between the studs 23, through cap 342, through topplate 20, and into joists or trusses 356. The threads on the screws biteinto the material of joists or trusses 356, and thus provide directanchor links, spaced along the length of the wall of the building,between the foundation wall 12 and the overlying floor whereby risk ofmovement of the overlying building structure off the foundation, e.g. inthe face of extreme environmental stresses, is substantially diminished.Screws 362 can be applied/inserted after erection of the foundation wallbecause of the availability of cavities 131 between the studs, so longas the joists/trusses 356 which receive screws 362 overlie cavities 131whereby such joists/trusses are laterally displaced, along the length ofthe wall, from studs 23.

Where a space is available within the overlying structure, such as abovethe bottom stringer of a floor truss, and as suggested in FIG. 7,vertically upwardly extending bolts 139 can be used in place of thevertically upwardly extending anchor screws 362, extending throughbracket 24A, bracket 48 where used, top plate 20, and the respectivetruss stringer, and nuts and optional washers can be used on the bolts,thereby to secure the truss, through the truss stringer, or otheroverlying structure to the underlying wall. Other vertically upwardlydirected mechanical fasteners such as nails can be used in place of therecited and illustrated screws and bolts, so long as the respectivefasteners provide the desired level of securement between the overlyingstructure and the underlying wall 10.

FIG. 7B illustrates an embodiment where cap 342 is omitted. A sillweather seal 357 is disposed between the top of panel 14 and the bottomof top plate 20. An exemplary suitable such seal 357 is a polyethylenefoam sold by Dow Chemical Company, Midland, Mich. under the name WEATHERMATE.

Angle bracket 24A extends generally most or all of the width of therespective cavity 131 between adjacent studs 23, and is mounted in thecorner where the upper portion of the panel meets top plate 20. Bracket24A is secured to the upper portion of the panel by screws 366 whichextend into, optionally through, inner layer 34. Screws 362 extendthrough angle bracket 24A upwardly through weather seal 357 and topplate 20 and into joists or trusses 356, thus securing top plate 20 andtrusses 356 to bracket 24A, whereby plate 20 and trusses 356 are securedto panel 14 by operation of screws 362, screws 366, and bracket 24A.Brackets 24A can be used in every cavity as desired, in alternatingcavities, or at otherwise-selected cavity spacings, depending on thestresses expected to be imposed on joists/trusses 356. Angle brackets24A can be similarly placed and secured by screws at the corner betweenthe bottom of the panel at inner layer 34 and the underlying footer orbottom plate, as illustrated in FIG. 7.

Returning again to FIG. 7, bottom plate 16, where used and asillustrated, can be a rather thin, e.g. about 0.18 inch to about 0.50inch thick, stiff and rigid resinous e.g. pultruded plate which hassufficient stiffness and rigidity to spread the vertical load for whichthe panel is designed, out over substantially the full downwardly-facingsurface area of the bottom plate, thus transferring the vertical load tothe underlying e.g. aggregate stone fabricated base or other base.

FIG. 7C shows that, as an alternative construct of a cap 342, outerflange 350 can extend upwardly as well as downwardly from plate 344,thus collectively lying adjacent the top of the underlying buildingpanel 14, adjacent top plate 20, and adjacent rim joist 354 wherebyfasteners 360 and 366A can extend through outer flange 350 and into topplate 20 as well as into rim joist 354 and joists/trusses 356 as well asinto outer layer 36, and end panels 44 of the stud.

In an embodiment, not shown, outer flange 350 can extend yet furtherupwardly, high enough to lie against, optionally cover the outer surfaceof, overlying plate 358 and/or the lower portion of the e.g. studframing which extends up from plate 358, such that fasteners can bedriven through outer flange 350 and into plate 358 and/or into suchoverlying stud framing. Thus, cap 342 can, as desired, tie together anyor all of the underlying wall, top plate 20, rim joist 354,joists/trusses 356, overlying plate 358 and framing overlying plate 358.

Referring again to FIG. 7, concrete slab floor 38 is shown overlyingthat portion of bottom plate 16 which extends inwardly into the buildingfrom the inner surface 57 of the main-run portion of panel 14, andinwardly from studs 23. Slab floor 38 abuts the inner surfaces of panel14 and studs 23, thus stabilizing the bottom end of the panel againstinwardly-directed forces which reach the lower end of the panel. Anglebracket 24A is seated in the corner defined by inner surface 25 of thewall and bottom plate 16. Screws or other fasteners (not shown) extendthrough the upwardly-extending flange of bracket 24A, securing thebracket to wall 10 at inner layer 34. Additional screws or bolts, notshown, can extend through the horizontally-extending flange, securingthe bracket to an underlying e.g. concrete footer.

Concrete anchors 158A extend through apertures 159 in studs 23 and intoconcrete slab 38, thus further securing wall 10 to slab 38 whereby wall10 is secured against movement away from slab 38, as well as beingsecured against movement of the wall toward the slab. Anchors 158A arespaced along the length of the wall at intervals of no more than 6 feet,typically at about 4-foot intervals.

While described using differing nomenclature, namely wall surface andinner surface, inner surface 57 and wall surface 25 both represent thesame face of building panel 14 when considered away from studs 23.Contrary to surface 25, inner surface 57 also includes the exposed studsurfaces, such as legs 128 and end panels 44 of the studs.

Inwardly-directed forces which reach the upper end of the panel areopposed by the attachments between overlying floor 40 and the upperportion of the wall. Inwardly-directed forces which are imposed on wall10 between the top of the wall and the bottom of the wall aretransferred, through the wall, to the top and bottom of the wall, thenceto the concrete floor and the overlying floor or floor system, by thestiffness and rigidity of the panel as collectively defined by theinteractions of the structure defined by e.g. layers 34, 36, 50, foamblocks 32, and studs 23.

In residential construction, a typical maximum downward-directedstructural vertical load experienced by an underlying e.g. foundationwall averages about 3000 pounds per linear foot to about 5000 pounds perlinear foot. In buildings contemplated by the invention, building panels14 are primary structural members which carry the bulk of such structureload which is ultimately imposed on the underlying natural base by thebuilding. The downwardly-directed load is typically applied to the fullwidth of the top of the wall, and can be applied anywhere along thelength of the wall.

In panels of the invention which include studs 23, which panels aresubjected to a downwardly-directed top-to-bottom load, distributed overthe thickness of the panels the panels deflect under such load in adirection toward the outer layer of the panel, namely toward the soilback-fill load. The bending resistance of the building panel limits thehorizontally-directed bending at the locus of maximum horizontalunderground loading thus accommodating bending of no more than L/120when supported in accord with ASTM E72. The vertical crush resistanceand the horizontal load bending resistance can be designed for greateror lesser magnitudes by specifying, for example and without limitation,density of the included foam; thickness of layers 34, 36, 50; use andparameters of additional reinforcement layers and/or intercostals, panelthickness, spacing, and/or depth “T1” of studs 23 or thickness “T” ofthe panel in combination with depth “T1” of the structure, as well asfiber orientation. For example, greater thicknesses of inner layer 34,outer layer 36, and/or intercostals 50, e.g. up to 0.5 inch, or 0.75inch, or more are contemplated where the overlying downwardly-directedloads, or the anticipated lateral loads, justify such thickercross-sections.

Above-ground side loads, such as wind loads, are less than typicalhorizontally-directed soil loads. Accordingly, the absolute bendingresistance capabilities of building panels intended for above-groundapplications may be less than the capabilities contemplated forbelow-grade loads. However, the L/120 capacity performance criteria arethe same, while contemplating lesser-intensity ultimate loads.

The Fiber

The reinforcing fiber materials used in products of the invention can beselected from a wide variety of conventionally available fiber products.Glass fiber has been illustrated in the general description of theinvention, and is believed to be the currently most cost effectivematerial. Other fibers which are contemplated as being acceptableinclude, without limitation, carbon fibers, Kevlar fibers, and metalfibers such as copper and aluminum, including nano-size embodiments ofsuch fibers. Other fibers can be selected to the extent theirreinforcing and other properties satisfy the structural demands of thebuilding panel in applications for which the panels are to be used, andso long as the fibers are not pre-maturely degraded in the useenvironment contemplated for the respective building panels.

The lengths, widths, and cross-sectional shapes of the fibers areselectable according to the demands of the structures in which thebuilding panels or other structures are to be used, and the processeswhich are used in fabricating such building panels. The overall fiberspecification includes multiple fibrous elements and is also known asthe fiber “schedule”. A given FRP layer e.g. 34, 36, 50 can includemultiple individually-Identifiable fibrous layers which, permissively,may be attached to each other e.g. by stitching, by fiber entanglement,or by other means.

The inventors herein have discovered that the positioning of the fibersrelative to each other, and the orientations of the fibers, in what willbe referred to herein as a “fiber substrate” or “base sheet”, as part ofthe “fiber schedule” has a substantial affect on the vertical crushstrength/resistance, as well as the degree of horizontal deflection, ofan upright wall when an overlying load is applied. An exemplary basesheet is a stitched, fiberglass cloth, having a first layer whereinabout 80-85% of the glass is continuous fibers oriented in a firstdirection and the remainder of the glass, also typically continuous, isoriented in a second direction perpendicular to the first direction,with the predominant fiber direction in the wall being directedgenerally vertically between the top of the wall and the bottom of thewall. Any given wall will have its specified fiber schedule, addressingthe fiber which is used in each FRP layer, in each portion of the lengthof the wall, e.g. around foam blocks 32 as well as the fiber which isused in the inner and outer layers.

Typically, at least about 50 percent by weight, optionally at leastabout 60 percent by weight, optionally at least about 70 percent byweight, of the fiber is continuous fibers which are oriented in thetop-to-bottom direction in the panel. Specifically, the continuousfibers which are oriented top-to-bottom, which may be up to about 90-95percent by weight of all the fibers in the panel, are continuous andextend in directions which are within 15 degrees of vertical, optionallywithin 10 degrees to vertical, optionally zero degrees to vertical,namely the fibers are vertical, when the panel is installed in avertical orientation in a building wall. Accordingly, the fiberstypically extend parallel to the vertical orientation of the studs whenthe panel is installed in a vertical orientation in a building wall.

Where the panel is fabricated using resin infusion molding, relativelyless dense fiber layers can be used in the architecture of the fiberschedule as flow control layers to facilitate resin flow during thepanel molding process. Such flow control layers are illustrated furtherin the discussion, following, of FIGS. 28 and 29.

The Polymer

The polymer which is used to impregnate and/or carry the fiber can beselected from a wide variety of conventionally available multiple-partreaction-curing resin compositions. Typical resin is a 2-part liquidwhere two liquid parts are mixed together before the resin is applied tothe fiber substrate. Third and additional components can be used in thereaction mixture as desired in order to achieve a desired set ofproperties in the cured resin. The resin mixture should be sufficientlyliquidous to be readily dispersed throughout the fiber schedule therebyto fill in all voids in the fiber schedule. Examples of useful reactioncuring resins include, without limitation, epoxy resins, vinyl esterresins, polyester resins, acrylic resins, polyurethane resins, phenolicresins, and recently-available eco-resins.

An example of such resin is Modar 814A® modified acrylic as the firstpart and peroxide-based Trigonox 44K® as the second part. The Modar814A® is available from Ashland Inc., Dublin, Ohio. The Trigonox 44K® isavailable from AkzoNobel, Chicago, Ill.

For any set of reaction materials which are used to make the reactedproduct referred to here, a conventional additive package can beincluded such as, for example and without limitation, catalysts,anti-oxidants, UV inhibitors, fire retardants, fillers, andfluidity-control agents, to enhance the process of applying the resinand/or curing the resin, and/or to enhance the properties of thefinished product, e.g. weather resistance, fire resistance, hardness,expansion/contraction and the like. For example, where fire suppressionis a consideration, a fire suppressing material, such as a metalhydrate, may be added to the resin, and mixed in thoroughly, while theresin is in its un-reacted liquid condition. A typical such firesuppressing material is alumina tri-hydrate. The amount of firesuppressing material to be used can be determined by testing samplestructures using known accepted test procedures. Such fire suppressingmaterial may be used in inner layers 34 and/or 34R and be omitted in theouter layers 36 and/or 36R and the intercostals 50, 150.

The Polymer/Fiber Composite

The polymer/fiber composite is addressed herein as a 2-part compositewhere the first part is the fiber, e.g. fiberglass, and the second partrepresents all non-fiber components of the composite. Thus, the secondpart, generally referred to herein as the resin, includes not only thechemically reactable resin components which react in forming theset/hardened resin, but also all other materials which are included inthe resin mixture in the fluid stage of the resin before the resin iscombined with the fiber. Thus, this second component includes, withoutlimitation, the various additives which are added to the materials whichchemically react to “set” the resin, as well as fillers and any othermaterials which do not chemically participate to any great extent in the“setting” reaction(s) wherein the resin transitions from a liquid phaseto a generally solid phase.

In general, dry fiber substrate, woven cloth, or fiber matt, is used asthe fiber base for structural portions of layers such as layers 34, 36,50; as well as for all other structural FRP elements of the inventionsuch as studs 23, and brackets 24, 24A, 48, 148, and 170. Since theobjective is to fill in substantially all voids in the fiber substratewith resin, enough resin is added to the fiber substrate to fill allsuch voids, whereby there should be no air inclusions, or so few airinclusions as to have no substantial effect on the physical or chemicalstability, or the physical properties, of a building panel or otherstructure built with such resin-impregnated fiber-based layer. Overall,the glass/resin ratio is as high as can be achieved, without leaving anysignificant, deleterious voids in the resultant layer once the resin iscured.

Given the requirement to minimize voids, the resultant structural layerproduct, e.g. layer 34, 36, or 50, or legs 128 or panels 44, is about 30percent by weight to about 65 percent by weight fiberglass, andcorrespondingly about 70 percent by weight to about 35 percent by weightof the second resin component. Optionally, the resultant layer is about40 percent by weight to about 60 percent by weight fiber and about 60percent by weight to about 40 percent by weight of the second resincomponent. A typical resultant layer is about 45 percent by weight toabout 55 percent by weight fiberglass and about 55 percent by weight toabout 45 percent by weight of the second resin component, optionallyabout 50 percent by weight fiberglass and about 50 percent by weightresin composition.

The top and bottom plates, as well as layers 34, 36, and 50 can be madeof such polymer/fiber composite. The bottom plate can be any materialwhich can bear the load imposed on the overlying building panel. Atypical bottom plate, where used, is an e.g. about 0.18 inch thick toabout 0.50 inch thick fiber-reinforced pultrusion, which is sufficientlystiff and rigid to spread the overlying load to the underlying footergenerally uniformly along the length of the panel

Top plate 20 can be made of, without limitation, fiberglass-reinforced,or other fiber-reinforced, resinous materials, or other materials suchas wood in the shape conventionally used for a top plate. It iscontemplated that a conventional wood-based top plate serves the purposeadequately, and provides for attachment of overlying wood elements suchas wood framing, using conventional fasteners and conventional fasteningmethods.

The Foam

The purpose of the foam, such as in a foam board or foam blocks 32 inthe main run wall section, and foam cores 32S in studs 23 (FIG. 28), isgenerally two-fold. First, the foam provides a certain level ofdimensional identity to that respective portion of the construct whilethe various foam and fiber elements are being assembled to each other inthe process of making a panel.

Second, the foam in foam board 32 or foam blocks 32 provides substantialthermal insulation properties in the resulting building panel construct.In achieving a desirable level of thermal insulation, foam having adensity of about 1.5 pounds per cubic foot (pcf) to about 8 pcf,optionally about 2 pcf to about 5 pcf, is selected. Foams less densethan the recited range of densities may not possess sufficient rigidityto stabilize the dimensions of the construct while the panel is beingassembled and cured. More dense foams than the recited range typicallyhave more structural strength, but provide less than the desired levelof thermal insulation, and are more costly. In general, the foams usedin the invention are dosed-cell foams although open-cell foams andpartially open-cell foams are contemplated as being operable in someimplementations.

Foam boards and blocks 32 and foam cores 32S can be made from a widevariety of compositions including, without limitation, extrudedpolystyrene foam, expanded bead polystyrene foam, rigid urethane foam,or polyisocyanurate foam. The foam can be rigid foam or flexible e.g.resiliently highly compressible foam. The foam is moisture resistant,preferably moisture proof, and is physically compatible with, and isgenerally chemically inert with respect to, the compositions andstructures of layers 34, 36, and 50 as well as with the compositions andstructures of the legs and end panels of the studs.

An exemplary foam board or foam block 32 has, without limitation,optional inner and outer skins 32SK (FIG. 29), and an expanded foam core32FC between the skins. The skins can be un-foamed extruded films madewith e.g. limestone-filled, fiberglass-reinforced polyester polymer.Skins 32SK are about 0.01 inch (0.25 mm) thick. Skins 32SK mayoptionally contain alumina tri-hydrate (ATH) or other fire retardantmaterial as an alternative to the limestone filler. Foam core 32FC canbe a polyisocyanurate foam having a density of about 2 pounds per cubicfoot. Similarly, a foam core 32S in a stud may have the same or similarskins 32SK either along legs 128 of the studs, or along end panel 44 andalong the opposing end of the stud.

Skins 32SK can be any thin material which provides a modest level ofprotection from mechanical shock or intrusion for the foam core. Forexample and without limitation, another material which can be used forskins is polyethylene film. Another material is fiberglass veil attachedto a layer of paper or other substrate which can give some dimensionalstability to the skin. Still another example is a thin layer of foamattached to a dimensionally relatively stable layer of paper or plasticfilm. In still other embodiments, there are no skins on foam blocks 32.

Regarding fixing the respective structural layers in their designatedpositions, the foam fills all, or substantially all, of the spacesbetween the respective surfaces of layers 34, 36, and 50, can optionallyform the cores of studs 23 and is in surface-to-surface contact with therespective fibrous layers as such layers are wrapped about therespective foam blocks. As the liquid resin is caused to flow around thefoam, and as the foam subsequently cures, the resin bonds to thecellular foam or the foam skin layer such that, in the finished buildingpanel, after the resin is cured, the respective FRP structural layersare adhered/bonded to the foam.

Turning to FIG. 15, outer layer 36 weaving layer 50, and foam blocks 32are the same materials, the same structures, and in the same relativepositioning as in the embodiment illustrated in FIG. 6. The primarydifference between the embodiment of FIG. 6 and the embodiment of FIG.15 is that, in FIG. 15, studs 23 are positioned between weaving layer50, at locations remote from outer layer 36, and inner layer 34. In suchstructures, studs 23 are held in the assembly by the entrapment of thestuds between weaving layer 50 and inner layer 34. Any bonding betweenstuds 23 and the weaving layer can operate to further hold, and fix, thepositions of studs 23 in the assembly. Location of studs 23 isillustrated in FIG. 15 as being on weaving layer 50 such that theweaving layer is between a foam block and the inner layer.

Another embodiment of building panels of the invention is illustrated inFIG. 17. In the embodiment of FIG. 17, each foam block 32 is wrappedwith one or more layers 190 of resin-impregnated fiberglass whichclosely and intimately wraps the longitudinally-extending outer surfacesof the foam block, optionally the entirety of the lengths of thelongitudinally-extending outer surfaces of the foam block, optionallyenclosing all sides of the foam block.

The resin may be added to the wrapped fiberglass layers on one or moresides of the foam blocks before the foam blocks are introduced into theprocess of assembling building panels of the invention. Such pre-addedresin in the wrapped fiberglass layers may be cured prior to assembly ofthe foam blocks into a panel. In the alternative, the resin may be curedalong with the curing of the resin in the inner and outer layers and/orin the studs.

As another alternative, the entirety of the resin used to consolidatethe wrapping layers and to bond the wrapping layers to the foam can beadded to, and dispersed in, the fiberglass layers which wrap around thefoam blocks after the foam blocks have been assembled with the remaininge.g. fiber elements of the panel structure.

The fiberglass can be a pre-woven or stitched matt of fiberglass whichis wrapped about a desired number of the sides of the foam block, or thefiber structure can be wrapped entirely about the foam block so as toform e.g. a butt joint or an overlapping joint where the ends of a wraplayer meet.

The fiber wrapping layer can represent an open pattern where some of thefoam surface is visible through the fiber wrapping after the wrappinghas been completed. In the alternative, the wrapping layer can representa dosed pattern where the fiber visually obscures substantially all ofthe underlying surface of the foam block.

Given the presence of the wrapping layers in the embodiment of FIG. 17,the wrapping layers 190 represent the intercostal reinforcing web whichextends between inner and outer layers 34, 36, whereby, weaving layer 50is not per se used as an additional element of the panel structure.

An exemplary process for making building panels of FIG. 17 is e.g. avacuum bag molding process, illustrated in FIG. 19. In FIG. 19, upperand lower layers of the vacuum bag are illustrated as 192A and 192Brespectively, and where the bag is still open for assembling of elementsof the structure being fabricated. As suggested by the illustration inFIG. 19, one or more layers of dry fiberglass pre-form, which willbecome outer layer 36, are laid out on the lower layer 192B of thevacuum bag. Foam blocks 32, pre-wrapped in dry fibrous layers 190, arelaid side-by-side on the outer layer pre-form. Pre-formed hollow-channelstuds 23 are added on top of the wrapped foam blocks. One or more layersof dry fiberglass pre-form, which will become the inner layer 34, arelaid over the top of the resulting subassembly, along with any desiredresin distribution layer. The vacuum bag is then dosed, vacuum is drawnand resin is admitted into the bag, whereby the resin enters the bag andpenetrates voids in the fiberglass layers, including layers 190. Innerlayer 34 collapses onto the profiles of studs 23, and the resin is curedin the bag according to conventional vacuum molding practice of fillingresin into the bag and curing such resin in the bag. In the vacuummolding process, layers 34 and 36, wrapped blocks 32, and studs 23, areall joined together as a unitary composite structure in a matrix whereinthe resin represents a generally continuous phase and the fiberrepresents either a discontinuous phase or a second continuous phase.Typically, both the resin phase and the fiber phase aregenerally-continuous phases.

FIG. 20 illustrates yet another embodiment of building panels of theinvention. In the embodiment illustrated in FIG. 20, the generalstructure of panel 14 is defined by foam blocks 32. Blocks 32 arepre-wrapped in fiberglass layers 190, the same as the pre-wrappingdiscussed above with respect to FIG. 19. Contrary to the FIG. 19structure, in the structure illustrated in FIG. 20, no separate studs 23are mounted at inner layer 34 to reinforce the building panel. Rather,every third foam block is oriented 90 degrees to the remaining blockssuch that the narrower edges 198 of the respective, so-oriented, wrappedfoam blocks are parallel to inner 34 and outer 36 layers. Thus, in FIG.20, foam blocks 32B, 32E, and 32H form a second set of foam blocks whichare so oriented. The remaining foam blocks, e.g. 32A, 32C, 32D, 32F,32G, and 32I represent a first set of foam blocks which defines thethickness “T” of the main run portion of the panel.

Blocks 32B, 32E, and 32H thus perform as structurally-reinforcingmembers, previously illustrated as studs 23 and/or intercostals 50, andare herein referred to as studs.

In the first set of foam blocks, the relatively wider sides 199 of thefoam blocks face toward the inner and outer layers. In the second set offoam blocks, the relatively wider sides 199 of the foam blocks facealong the length of the building panel.

Given the structural orientation of foam blocks 32 in FIG. 20, desirablewidth and thickness dimensions for the wrapped foam blocks, includingthe foam block studs, including the wrapping layers 190, are 6.5 incheswidth and 3.0 inches thickness. Such dimensions provide a commonly-useddepth “T1” of the channel 131 between the studs, of about 3.6 inches,assuming that the thickness of inner layer 34 is relatively negligible.The illustrated structure, and again assuming negligible thickness ofinner layer 34, also provides a commonly-used center-to-center distance“T2” between the foam block studs of 16 inches.

Given the above dimensions, the depth “T1” of channel 131 between a pairof adjacent studs is the same as conventional depth, namely 3.6 inches,the same as the depths of the channels between conventional wood studs,and a width of 13 inches. Further, the 16 inch center-to-center spacingof the foam block studs provides for conventional attachment ofconventional building materials such as 48-inch wide sheeting 129 on theinside of the building panel.

In the embodiment illustrated in FIG. 21, the width of stud 23, definedbetween legs 128, is 1.5 inches. Given a center-to-center “T2” distancebetween studs 23 of 16 inches, the width of channel 131 between adjacentones of the studs is 14.5 inches, which corresponds to the conventionalwidth of commercially available, but compressible, panels of fiberglassbatt insulation.

FIG. 22 illustrates a building panel made using a series of laid-flatindividually-wrapped foam blocks 32 in combination with spaced hollowpultruded studs 23. An outer layer 36 extends along the bottom of thestructure illustrated. An inner layer 34 extends along the top of thestructure illustrated, and overlies both foam blocks 32 and studs 23. Agiven stud 23 extends from a dosed end wall 126 at outer layer 36, alonglegs 128, past the main inner surface 25 of the panel at inner surfacesof blocks 32, and passes further inwardly of blocks 32 and away fromouter layer 36, to end panel 44.

An inner layer 34 of fiberglass-reinforced polymer overlies both thelaid-flat blocks 32 and studs 23.

FIG. 23 illustrates a vacuum infusion molding process which can be usedto make building panels of the invention. FIG. 24 illustrates a buildingpanel made by such vacuum molding process.

Referring to FIGS. 23 and 24, a specific example of an infusion processof making a building panel of the invention is described in some detailwhere dry fiberglass, containing no resin is loaded into the mold, themold is closed and sealed; air is evacuated from the dosed and sealedmold, and resin is infused into the mold as the air is being evacuatedfrom the mold. In FIG. 23, the numeral 300 represents a lower rigidfemale mold element which includes a plurality of elongate femalerecesses 302 spaced e.g. 16 inches apart center-on-center. Numeral 306represents a rigid upper mold element.

At the beginning of the process, the upper and lower mold elements,including recesses 302, are optionally coated with mold releasematerial. In the alternative, a mold release agent can be incorporatedinto the resin. Next, foam stud blocks 328, pre-wrapped with layers 308of fiberglass, are placed into recesses 302. Foam stud blocks 32S andrecesses 302 are so sized and configured that the foam blocks fit snuglyin the recesses, and the top surfaces of the foam stud blocks aregenerally co-planar with the upper surface 304 of the lower moldelement.

Next, a layer 334 of fiberglass fabric, which will become inner layer 34of the so-fabricated building panel, is unrolled from a roll of suchmaterial mounted adjacent e.g. the right end of the mold table and ispulled over the lower mold element, e.g. from the right side to the leftside, all as illustrated in FIG. 23. The layer of fabric is laid overthe entirety of the length and width of the lower mold element,including over the top surfaces of stud blocks 328.

Next, foam blocks 32, pre-wrapped with layers 314 of fiberglass (FIG.24), are laid flat on top of the fabric, edge-to-edge as illustrated inFIG. 23.

Next, another layer 336 of the fiberglass fabric, which will become theouter layer 36 of the so-fabricated building panel, is unrolled from theroll of such material mounted adjacent e.g. the right end of the moldand is pulled over the laid-flat foam blocks 32, from the e.g. rightside of mold 300 to the left side of the mold. Layer 336 of dry fabricis laid over the entirety of the assemblage of foam blocks 32, 328,whereby layer 336 becomes the top surface of the construct.

The upper and lower mold elements are brought together, with a sealtherebetween, so as to form a dosed and sealed mold, with the respectiveelements of the building panel in the mold cavity.

The mold cavity is then evacuated at a first location on the mold,drawing a vacuum which removes substantially all of the air out of themold cavity. As the air is withdrawn from the mold cavity, curableliquid resin is fed into the cavity at a resin feed port located at e.g.an opposing side or end of the mold. The resin flows to all areas of themold where air has been removed, thus to fill the voids left by theevacuating air and to form the continuous resin matrix about and throughall of layers 334, 336, and the wrapping layers 308 and 314 offiberglass which encompass foam blocks 32 and 32S.

Thus, resin flows into intimate bonding contact with the top surfaces offoam blocks 32S. Resin also flows into intimate bonding contact with thetop surfaces of foam blocks 32. As a result, the resin in the mold flowsto all areas which have been evacuated by the removed air, thus creatinga continuous matrix of resin throughout the structure in all of thefiberglass layers which are in the mold. In instances where the foam infoam blocks 32 and 32S is a closed cell foam, the resin does notpenetrate generally beyond the outer surfaces of the foam blocks. Wherethe foam is an open-cell foam, or partially open-cell foam, the resincan penetrate more deeply into the foam blocks as permitted by thepermeability of the foam.

Once the mold has been dosed and evacuated, and the necessary quantityof resin has been infused into the mold, the mold is maintained in itsdosed and sealed condition until the resin in the mold has cured. In theprocess of curing the resin, the mold may be heated, or not, dependingon the thermal requirements associated with the curing of the specificresin being used. Where heat is required, heat is applied. Where heat isnot required, the resin is typically cured in an ambient environmenttemperature of e.g. 60-80 degrees F.

The cured fiber-reinforced polymeric building panel product is removedfrom the mold. FIG. 26 illustrates a building panel made according tothe process described with respect to FIG. 23.

FIG. 25 shows a top portion of the panel of FIG. 26, illustrating firstand second draft angles at the top of the panel. A first draft anglebetween the inner surface 25 and end panels 44 of the studs has anincluded angle “DA”, and is typically about 1 degree to about 25degrees, using a line perpendicular to outer surface 56 of the panel asthe base line “BL” for the angle. A second draft angle between outersurface 56 of the panel and inner surface 25 has an included angle “DB”,less than the angle DA, of at least 0.25 degree to about 15 degrees.Typical angle for “DB” is about 0.25 degree to about 0.5 degree. Typicalangle for “DA” is about 2 degrees to about 3 degrees. Angles below therecited ranges can result in difficulty in removal of the panel from themold. Angles greater than the recited angles can result in use ofadditional panel materials in the mold. Use of first and seconddifferent draft angles results in use of less resin during the moldingprocess.

The draft angles shown in FIG. 25 are molded into panel 14 bycorresponding draft angles at the top end of the mold. Given the draftangles used at the top end of the mold, the bottom end of the mold canbe configured perpendicular to the inner/outer surfaces of the panelwhereby the bottom of the panel, as molded, is perpendicular to theouter/inner surface of the panel.

While draft angles are shown at the top of the panel, with correspondingdraft in the mold, such drafts can as well be used at the bottom of thepanel and mold whereby the top of the panel can be molded perpendicularto the inner/outer surfaces of the panel.

While different draft angles have been illustrated for both the studsand the main run portion of the panel, in some embodiments, a singledraft angle can be used for the full thickness of the panel betweenouter layer 36 and end panels 44 of the studs. In some embodiments, thedraft angle can be limited to the studs whereby no draft angle need beused between the inner and outer layers.

For ease of release from the mold, stud legs 128, as well as the foamcore, can define draft angles extending from end panels 44 to locationsproximate inner surface 25 such that the studs are wider proximate innersurface 25 than at end panels 44. Such draft angles on the stud legs andfoam core are about % degree to about 20 degrees, optionally about 1degree to about 2 degrees.

Once the panel has been removed from the mold, any material representingany draft angles is trimmed off the top and/or bottom of the panel withe.g. a ring saw or other known device capable of cutting FRP materials,both to shorten the panel to specified length, and to provide surfacesat the top and bottom of the panel which are perpendicular, withincutting precision capabilities, to the outer surface of the panel, suchthat when the panel is installed in fabricating a vertical wall, the topand bottom of the panel present horizontal surfaces for interfacing witha footer or bottom plate, as well as for interfacing with overlyingstructure.

The process of FIG. 23 can be used to make building panels which arecost effective in use of materials, and which are readily combined withconventional building materials using conventionally-recognized andstandardized building elements spacings. In the embodiment illustratedin FIGS. 23-24, foam blocks 32, including the wrapping layers and resin,are 9 feet long, 8 inches wide, and 3 inches thick between layers 34 and36. Stud foam cores 32S extend 3.6 inches from layer 34, and are 1.5inches wide, and 9 feet long. Layers 34 and 36 are 9 feet wide and aslong as the length of the panel. Layers 308, 314, 34, and 36 canoptionally all be made of the same 22-ounce fiberglass fabric and arethus all the same thickness when filled with resin. The resultingthickness of each such layer is about 0.08 inch (2.0 mm). In the givenstructure, outer layer 36 plus the adjacent portion of wrapping layer314 is thus 0.16 inch (4.1 mm) thick. Similarly, inner layer 34 plus theadjacent portion of wrapping layer 314 is 0.16 inch (4.1 mm) thick.Also, the collective thickness of the reinforcing portions 309 of thetwo wrapping layers which are disposed between each pair of foam blocks32 is 0.16 inch (4.1 mm), thus collectively defining intercostals 50.

In the alternative, the inner layer, the stud layers, and theintercostal layers can be somewhat thicker than the outer layer. Forexample, the outer layer may have a thickness of about 0.15 inch toabout 0.19 inch while the inner layer, the stud layer, and theintercostals may each have thicknesses of about 0.19 inch to about 0.25inch.

When the building panel is being used in a building, the outer surfaceof the building panel is stressed by side loading e.g. back-fill soil,and/or by water pressure, or is periodically side-loaded by wind loadingif the panel is used above ground. The inner layer is stressed intension resulting from the side loading. The reinforcing intercostal webportions 50 and the stud skins are stressed both by side loading andcompression loading. Thus, all of the highly stressed areas of thebuilding panel are developed at a common thickness of the fiberreinforced polymeric material, resulting in an efficient use ofmaterials and structure.

In the building panel illustrated in FIG. 26, foam blocks 32, wrapped infiberglass layers, are laid side-by-side, the same as are foam blocks 32in FIG. 24. Stud cores 23 are illustrated as being pultruded rectangularhollow tubes which lie against the wrapped foam blocks. Stud cores 23Scan, as desired, be elongate foam blocks. Further, studs 23 and/or studcores 23S need not be pultruded, and thus can be made by any of theprocesses known for making fiber-reinforced cured FRP structures.Further, in any of the embodiments, stud cores 23S can be othernon-flammable structural material such as the earlier-mentioned steelstud profiles.

Returning to FIG. 26. FRP inner layer 34 overlies studs 23 thus trappingthe studs between the inner layer and the foam blocks. FRP outer layer36 lies against foam blocks 32 on the opposite sides of the blocks fromthe inner layer. An additional reinforcing layer 36R is disposedoutwardly of outer layer 36 such that layer 36 is between layer 36R andwrapped foam blocks 32.

The specifications for layer 36R, including fiber content, polymercontent, polymer selection, layer thickness, and method of making thelayer are typically the same as for layers 34 and 36.

In some embodiments, layer 36R is added to a section of a building panelor a wall, optionally less than the entirety of the building panel orwall. Layer 36R may be added to layer 36 by e.g. adhesively mounting afiberglass layer to layer 36 and then brushing or otherwise adding resinto the fiberglass layer, thus to fill the matrix represented by thefiberglass layer, with resin, or simply by placing the fiberglass layeron layer 36 and adding curing liquid resin to the fiberglass layer,whereby the added resin provides the bonding between layers 36 and 36R.The fiber-resin combination is then cured, thereby creatingstructurally-effective reinforcing layer 36R.

Layer 36R can be used selectively e.g. in locations on a wall where peakloads are expected to be applied to the wall and wherein remainderportions of the wall have adequate strength to tolerate the loadsexpected to be applied at such remainder portions and so do not includelayer 36R. Such selective, and limited, use of reinforcing layer 36Radds to cost-efficiency of the wall by allowing a substantial portion ofthe length of the wall to be specified for less capacity than is neededat the peak load locations, and using layers 36R to strengthen the wallat such peak load locations.

A reinforcing layer such as a layer 36R can be used in association withthe outer layer of the wall to strengthen the wall at the outer layer,or can be used in association with the inner layer to strengthen thewall at the inner layer, or can be used at both the outer layer and theinner layer. The reinforcing layer, whether inner layer or outer layer,can be continuous along the length of the wall, or can be discontinuous,used e.g. only where peak loads are to be applied to the wall.

A second reinforcing layer 34R is illustrated in FIG. 25, in combinationwith reinforcing layer 36R. Layer 34R is shown disposed inwardly ofinner layer 34. Layer 34R is shown covering layer 34 only in two ofcavities 131. Thus, layer 34R illustrates the principle that layer 34Rcan be employed to provide localized increased strength in the panel,namely around a peak load region of the wall. Similarly, reinforcinglayer 36R, shown covering the entirety of outer layer 36 in FIG. 26, canalso be used on only part of the length of the building panel, or onlypart of the length of the wall. Contrary to the illustration in FIG. 26,namely in an embodiment not shown, inner layer 34R can, in thealternative, extend over and about studs 23 whereby layer 34R iscontinuous from one channel 131, about a stud, and into an adjoiningchannel. Layer 34R can be continuous to so extend over any number of thestuds and into any number of the channels 131. Layers 34R and 36R areboth optional. Layers 34R and 36R may each or both be used over onlypart of the length of the wall, or may be used over the entire length ofthe wall. Wherever a layer 34R or 36R is used, the respective layer istypically applied over substantially the entire height of the respectivebuilding panel.

The panel illustrated in FIG. 26, including layer elements 34R asspecified, can be made by a vacuum infusion molding process such as thatillustrated in FIG. 23. First, any reinforcing layer fiberglass 34R islaid in the bottom of the mold, including into recesses 302 asspecified. Next, the fiber precursor to layer 34 is laid over the layer34R fiberglass in the bottom of the open mold, and is worked intorecesses 302. Studs 23 are then placed into recesses 302, pushing layer34 fully into recesses 302 in the process, with the result that thelayer 34 is laid generally flat between adjacent recesses 302, and thetops of the studs are generally co-planar with the top of layer 34.

Next, foam blocks 32, pre-wrapped with fiberglass layers 314, are laidflat on top of studs 23 and layer 34, edge to edge in the mold.

Next, layer 36 fiberglass is placed on top of the wrapped foam blocks,and layer 36R fiberglass, if specified, is placed on top of the layer 36fiberglass.

The mold is then dosed and evacuated, and resin is infused into the moldand cured. Layers 34R may be incorporated into the panel during themolding process, or can be added as desired, e.g. for localizedreinforcement, after the panel is removed from the mold.

As elements of the panel, and when talking about the fiber content ofrespective layers, the fiber is sometimes referred to herein asfiberglass “layers” and is described in terms of the FRP layers intowhich such fiberglass layers will be incorporated in the resin-infusedfinished product. Those skilled in the art understand that the fiberlayers are exactly that, fibrous layers, and that designating suchfibrous layers in terms of the layers of the finished panel is done forsake of simplicity of the description. Those skilled in the art willrecognize that the resin has not been added to the panel precursorunless so stated, whereby the layer designation applies to the fiberalone, and that such fiber ultimately becomes part of the recited FRPlayer.

FIG. 27 shows a building panel having no intercostal reinforcements,namely no intercostal webs 50, no other reinforcement extending betweenthe inner and outer layers. FIG. 27 does show an intermediate layer 39between studs 23 and a foam board 32BD. Foam board 32BD is generallycontinuous along the full height and width of the building panel, andacross the full thickness of the building panel between intermediatelayer 39 and outer layer 36. Specifications for foam board 32BD,including polymer content, density, rigidity, and the like, are the sameas for foam blocks 32 illustrated with respect to other embodiments ofthe invention. Specifications for intermediate layer 39, including fibercontent and orientation, polymer quantity, polymer composition, layerthickness, and method of making the layer may be the same as for any oflayers 34 and 36, or may be specified differently. Such layer 39 isconveniently affixed to the foam board with any of theconventionally-known effective construction adhesives, or layer 39 maybe incorporated into the panel in the process of making the panelwhereby the resin affixes layer 39 to the foam board.

FIG. 27 also shows a reinforcing layer 36R disposed outwardly of outerlayer 36 such that outer layer 36 is between reinforcing layer 36R andthe foam board 32BD. The specifications for layer 36R in the embodimentsof FIG. 27, as with the embodiments of FIG. 26, including fiber contentand orientation, polymer quantity, polymer composition, layer thickness,and method of making the layer, may be the same as for any of layers 34and 36, or may be different. Such layer is conveniently affixed to outerlayer 36 with any of the conventionally-known effective constructionadhesives, or layer 36R may be incorporated into the panel in theprocess of making the panel whereby the resin affixes layer 36R to thefoam board. Layers 36R and 39 are both optional.

The panel illustrated in FIG. 27 can be made by the vacuum infusionprocess of FIG. 23. First, fiber layer 34 is laid in the bottom of theopen mold and is worked into recesses 302. Studs 23 are placed intorecesses 302, pushing layer 34 fully into recesses 302 in the process,with the result that layer 34 is laid generally flat adjacent recesses302 and the tops of the studs are generally coplanar with the top oflayer 34 outside the recesses.

Next, a foam board 32BD, which extends the length and width of the mold,is laid on layer 34.

Next, layers 36 and 36R are sequentially laid on the foam board. Themold is then closed, sealed, and evacuated; and resin is infused intothe mold and cured.

In any of the infusion molded product, flow channels are created asneeded, optionally including through the foam board, in order tofacilitate flow of the resin into substantially all of the space insidethe mold.

FIGS. 28 and 29 show yet another embodiment of building panels of theinvention. The embodiment of FIGS. 28-29 uses foam blocks 32 in aside-by-side relationship in the main run portion of the panel, an outerlayer 36, an inner layer 34, and studs 23.

Each foam block 32 has an outwardly-facing surface 32FS, aninwardly-facing surface 32IF, and opposing side-facing surfaces 32SFwhich connect the inwardly and outwardly-facing surfaces. In theembodiment of FIGS. 28-29, a layer 190 of fiberglass is wrapped abouteach foam block, covering outwardly-facing surface 32FS and the twoside-facing surfaces 32SF. The fiberglass is typically a woven orstitched mat wherein continuous fibers, representing e.g. about 60percent by weight to about 90 percent by weight, optionally about 70percent by weight to about 85 percent by weight, of the fiberglass mat,extend along the lengths of the foam blocks, thus along thetop-to-bottom height of the panel. The edges of the fiberglass wrappinglayer are drawn about the corners of the foam block where theside-facing surfaces meet inwardly-facing surface 32IF, and terminateproximate those corners, and staples 372 are driven through thefiberglass layer near the respective edges of the fiberglass layer, andinto the foam blocks on inwardly-facing surface 32IF, thus securing thefiberglass wrapping layer to the foam block. With a foam block sowrapped, and before such foam block is assembled into a panel 14, theinwardly-facing surface 32IF of the foam block is thus not overlaid byfiberglass layer 190, and remains exposed. In the alternative, layer 190can extend across the entirety of inwardly-facing surface 32IF, thoughat additional cost.

In the embodiments of FIGS. 28 and 29, those portions of layers 190which overlie the outwardly-facing surfaces 32FS of the foam blockscollectively define the structural portion of the fibrous reinforcementfor outer layer 36, and thus are marked with layer 36 designations. Anadditional flow-control layer 36F of fiberglass overlies the wrappedfoam blocks.

The inwardly-facing surfaces of the foam blocks are covered by an innerflow-control layer 34BF of fiberglass.

Still referring to FIGS. 28-29 a stud 23 has a core defined by a studfoam block 32S. Stud foam block 32S has an inwardly-facing surface 32SIFfacing away from inner flow control layer 34BF, two side-facing surfaces32SSF, and an outwardly-facing surface 32SOF facing toward flow controllayer 34BF.

A layer 308 of fiberglass is wrapped about each stud, coveringinwardly-facing surface 32SIF and the two side-facing surfaces 32SSF.The edges of the fiberglass wrapping layer 308 are terminated at thecorners of the stud foam block which are defined where a side-facingsurface 32SSF of foam block 32S meets the outwardly-facing surface 32SOFof foam block 32S. Staples 372 are driven through fiberglass layer 308and into foam block 32S adjacent the corresponding corners, thussecuring the fiberglass wrapping layer to the respective foam block 32Sbefore the wrapped stud precursors are assembled into a panel.

Inner layer 34 of the panel covers/overlies flow control layer 34BF andwraps about each of the studs, namely about the outwardly-facing surface32SOF and the two side-facing surfaces 32SSF of the studs.

FIG. 29 is an enlarged view of a portion of the panel shown in FIG. 28and thus shows especially the fiberglass schedule in more detail.Starting at outer surface 56 of the panel, layer 36F is a flow controllayer which facilitates flow of resin during a vacuum infusion processof making the panel. An exemplary fiberglass material for layer 36F isdescribed as one ounce per square foot continuous filament matt (CFM)fiberglass.

Referring again to FIG. 29, layer 190 is seen to be composed of twosub-layers. A flow-control sub-layer 190F is disposed against theoutwardly-facing surface 32FS, and the side-facing surfaces 32SF, of afoam block core 32FC. A structurally more robust sub-layer 190S, whichprovides the bulk of the strength of layer 36, is disposed between flowcontrol layer 190F and outer flow control layer 36F.

An exemplary material for layer 190 embodies a total of 55-ounces persquare yard of fiberglass. Layer 190 has a first sub-layer defined by51-ounces per square yard of fiberglass rovings, with the rovingsoriented along the top-to-bottom height of the panel and designated as190S, and a second sub-layer has 4-ounces per square yard of fiberglass,as sub-layer 190F, oriented perpendicular to the rovings in sub-layer190S; with sub-layers 190F and 190S stitched together to form a singlestructural fiber-reinforcing element which is used as the fiberreinforcement layer 190.

The upwardly-oriented fibers in a vertical panel are oriented zerodegrees to about 15 degrees from vertical in order to take advantage ofthe inventors' discovery that such upright orientation of a substantialportion of the fibers provides a significant increment to vertical crushstrength of the panel. Typical orientation is within 10 degrees,optionally within 5 degrees, optionally within 3 degrees, of vertical.

The fraction of fibers which are so upwardly oriented is at least about50% by weight of the fiber in the panel, optionally at least about 60%,optionally at least about 70%, optionally about 80-85% by weight.

Still referring to FIG. 29, layer 308, which wraps stud foam blocks 32S,is seen to be composed of two sub-layers. A structurally more robustsub-layer 308S, which provides the bulk of the strength of layer 308, isdisposed against the inwardly-facing surface, and the side-facingsurfaces, of stud foam blocks 32S. A flow control sub-layer 308F isdisposed outwardly of sub-layer 308S such that sub-layer 308S ispositioned between stud foam block 32S and flow control sub-layer 308F.

An exemplary material for layer 308 is the same 2-layer fiberglassmaterial used in layer 190, with the 51-ounce per square yard rovingssub-layer 308S disposed toward the stud foam block 32S and oriented inalignment with the lengths of the studs, and with the 4-ounce per squareyard flow control sub-layer 308F disposed relatively away from the studfoam block 32S and oriented perpendicular to sub-layer 308S.

Again referring to FIG. 29, layer 34 is seen to be composed of 2sub-layers. A structurally more robust sub-layer 34S is disposed againstlayer 348F between studs 23, and against flow control layer 308F aboutstuds 23. A flow control sub-layer 34F is disposed outwardly ofstructural sub-layer 34S such that sub-layer 34S is between flow controllayers 34F and 308F.

In an exemplary panel as illustrated in FIGS. 28-29, foam blocks 32 arenominally 3 inches thick and 8 inches wide while the respective layersare about 0.15 inch to about 0.25 inch thick. For purposes offacilitating visualization of the ends of layer 190 on theinwardly-facing surfaces 32IF of foam blocks 32 in FIGS. 28-29, a spaceis shown, in FIG. 29, at the inwardly-facing surface of each foam block32 between the facing ends of layer 190. Those skilled in the art willrecognize that, in light of the distortion of the relative dimensions ofthe foam blocks versus the thickness of the FRP layers, the spaces shownat the surfaces of the foam blocks are actually of nominal, if any,thicknesses whereby, during the process of drawing vacuum in the mold,and infusing resin, the vacuum causes the fiberglass of layers 348F and34 to collapse toward the surfaces 32IF of the foam blocks. Under thesame influence of the vacuum, the ends of layer 190 which wrap thecorners at that surface become compressed, and resin fills any remainingvoids proximate such ends, whereby the illustrated spaces are in factfully occupied by fiber and resin, and do not exist as spaces in themolded, cured panel.

FIG. 28 illustrates three embodiments of use of an anchor 158, 158A,158B, first introduced at FIG. 7, at the base of a stud. Such anchorsare used to tie together a concrete slab floor and the building panel,at the base of the building panel. Accordingly, such anchor is locatedbelow the height of the top of the concrete slab such that the anchor isembedded in the concrete slab e.g. at about the mid-point of the depthof the concrete slab. In each instance, the anchor extends through anaperture in the stud, and extends outward from the stud into space whichis occupied by the concrete slab.

In the first instance, the anchor is indicated, in FIG. 280, in solidoutline at 158, extending through a stud 23, including through legs 128.Anchor 158, as illustrated, is generally parallel to inner surface 25 ofthe panel and generally parallel to the bottom of the panel. Anchor 158extends from both sides of the stud, and continues in a straight linepart way across channel 131. In the illustrated embodiment, anchor 158extends e.g. 2-6 inches away from each leg 128 of the stud.

In the second instance, the anchor is indicated, in FIG. 28, in dashedoutline at 158A. What was a straight-line anchor 158 has beenfabricated, at 158A, into an open loop, with the open side of the loopextending away from the panel.

In the third instance, the anchor is indicated, in FIG. 28, in dashedoutline at 158B, continuing in a straight line across the channels 131and through each of the studs. In this embodiment, the anchor iscontinuous, or generally continuous, or effectively continuous, andextends the full length of the panel, including through adjacent ones ofthe studs.

The actual configuration of the anchor is not critical so long as theanchor can be suitably mounted in the panel, and extends into the3-dimensional space which is occupied by the concrete slab floor. Whereindividual anchors are used, the anchors are spaced dose enough to eachother to securely connect the slab to the wall. Typical spacing foranchors which anchor a conventional concrete wall to a conventionalconcrete footer or to another type of underlying concrete wall is 6 feeton center between anchors, and so 6 feet on center is believed to be anacceptable spacing for any configuration of anchors 158 or 158A. Thespacing can be adjusted, closer, or farther apart, according to thestructural needs of the building.

Anchors 158, whatever the configuration from the top view, can readilybe fabricated from e.g. ⅜ inch (0.95 cm) to ½ inch (1.3 cm) diametersteel reinforcing rod stock. Such stock can be cut, bent, and otherwisefabricated into a wide variety of outlines, configurations for insertioninto and through studs 23.

In the alternative, anchors 158, 158A, 158B can be FRP products thus toavoid the negative features of using steel in an environment which canbecome wetted with water. For example, anchors 158, 158B can befabricated from pultruded rod stock. Similarly, anchors 158A can bemolded FRP articles.

In any infusion molding process, it is critical that resin infuse all ofthe fibrous elements of the panel precursor which is in the mold. Thepurpose of flow control layers 36F, 190F, 34BF, 308F, and 34F is tofacilitate flow of liquid resin throughout the panel construct duringthe process of fabricating the panel using a vacuum infusion moldingprocess, thus to accomplish full and uniform distribution of resinthroughout the mold. While exemplary flow structures have been describedas 1 oz/sq ft (34 g/sq meter) CFM and 4 oz/sq ft (135.5 g/sq meter)(randomly oriented), both uni-directionally oriented, a wide variety offibrous structures are available, which have characteristics compatiblewith facilitating resin flow in the precursor assembly. And, theinvention contemplates use of flow-control layers in a variety of otherlocations, depending on the detail of the structure and location ofother elements of the panel profile.

In addition to the flow control layers, which are illustrated herein,foam blocks 32 and/or 32S, or other panel elements, can be provided withelongate flow channels/grooves in order to further facilitate flow ofresin throughout the panel construct in a resin infusion process. Yetfurther, the fiber webs can be provided with spaced apertures tofacilitate flow of resin through the webs at such specified locations.

In the embodiments illustrated in FIGS. 28-29, using the fiber layersand layer specifications given herein, and using a vacuum infusionprocess for making panel 14, after curing of the infused resin, innerand outer layers 34 and 36, each including its corresponding flow layersand sub-layers, if any, are each about 0.13 inch to about 0.25 inch (3.8mm to 6.4 mm) thick. The combined thickness of the polymer-infusedfiberglass layers, cured, at the facing side-surfaces of each set ofadjacent facing blocks is about 0.15 inch to about 0.25 inch (3.8 mm to6.4 mm) thick, thus creating an intercostal 50 having correspondingthickness. The combined thickness of layers 34 and 308 at the outersurfaces of studs 23 is about 0.15 inch to about 0.25 inch (3.8 mm to6.4 mm). At each stud 23, one of the legs is typically aligned with acorresponding one of the intercostals 50. Foam blocks 32 are about 3.2inches thick and about 2 lbs/ft³ density. Studs 23 extend about 3.6inches from surface 25.

In such a panel, which is 9 feet (2.7 meters) high, lateral deflectionat rated vertical and horizontal loads can be limited to no more thanabout 0.9 inch anywhere on the panel.

Referring to FIGS. 28-29, the main run portion of a typical buildingpanel, for use in underground residential applications such asfoundation walls for single-family homes, has a nominal thickness “T” ofabout 3.4 inches. Studs 23 are about 1.6 inches wide and projectinwardly about 3.6 inches from outermost surface 25 of inner layer 34 atthe main run portion of the panel at surface 25. Inner layer 34 is about0.19 inch to about 0.25 inch thick. Outer layer 36 is about 0.13 toabout 0.19 inch thick. Intercostals 50 are about 0.19 inch to about 0.25inch thick. Studs 23 have walls about 0.19 inch thick to about 0.25 inchthick. The foam in foam blocks 32 and in studs 23 is polyisocyanuratefoam having density of about 2.0 pcf. Such building panel has a mass ofabout 55 pounds per linear foot, a verticalcrush-to-catastrophic-failure capacity at least of about 15000 poundsper linear foot, and a horizontal bending resistance, when loaded at itsdesigned load, of at least L/120, optionally at least L/180, optionallyat least 11240, where “L” is the straight line dimension of the panel,top to bottom, when the panel is installed in an upright orientation.

Depending on the safety factors desirably built into the buildingpanels, and given a known typical load capacity of 15000 pounds perlinear foot in the above-illustrated example, the absolute verticalcrush-to-catastrophic-failure capacity can be engineered to be as littleas about 4000 pounds per linear foot, optionally at least about 6000pounds per linear foot, typically at least about 8000 pounds per linearfoot. At least 10,000 pounds per linear foot can be specified, as can atleast 12,000 pounds per linear foot, namely any capacity up to themaximum known capacity with the above-recited layer thicknesses, of upto about 25,000 pounds per linear foot. Panels of the invention havebeen tested/loaded according to ASTM E72 to catastrophic failure ataxial, e.g. top-to-bottom loads up to 26,700 pounds per foot length ofthe panel. Correspondingly, using a safety factor of 3×, such panels cantolerate up to 8900 pounds per foot axial load in a building, whichtypically exceeds both the load-bearing capacity of the underlyingnatural soil and the load imposed by an overlying e.g. low-densityresidential building.

The panels illustrated herein, which incorporate foam cores in theirstuds, can be made by the vacuum infusion method provided that suitableprovisions are made for resin flow, such as the flow control layersdescribed with respect to FIGS. 28 and 29, and/or flow channels in thefoam blocks or other elements of the panel. Such panels can also be madeby other processes, such as the well-known open mold wet lay-up process.

FIG. 30 illustrates an embodiment where layer 39 is retained but layer36R has been omitted. In FIG. 30, the respective layers are representedby single lines. The structure of FIG. 30 includes foam board 32BD,outer layer 36 on an outer surface of board 32BD, intermediate layer 39on an inner surface of board 32BD, inner layer 34 overlying intermediatelayer 39, and studs 23 between intermediate layer 39 and inner layer 34.Layer 39 can be omitted such that studs 23 lie directly against foamboard 32BD. FIG. 30 further illustrates male 216 and female 218 ends onthe panel. Male end 216 is shown as hollow, but can, as desired, befilled with thermally insulating foam discussed elsewhere herein.

FIG. 30 illustrates a panel 14 devoid of intercostals 50. Forstrength-enhancing features, panel 14 of FIG. 30 employs studs 23 andintermediate reinforcement layer 39, in addition to inner and outerlayers 34, 36. Further, inner layer 34 extends over studs 23 wherebystuds 23 are trapped between inner layer 34 and reinforcement layer 39.FIG. 30 shows spacing the studs 16 inches apart, with correspondingspacing of the male and female panel ends so as to accommodate commonconstruction protocol across joints between panels, which protocolspaces studs e.g. 16 inches apart along the length of the wall forpurposes of interfacing such studs with commonly-sized andcommonly-available construction materials.

In the illustrated embodiments, a variety of spacing elements have beenshown interposed between the inner and outer layers, spacing the innerand outer layers from each other, and fixing the dimensional spacing ofthe inner and outer layers with respect to each other. The illustratedspacing elements include foam board 32BD, multiple foam blocks 32,intercostal webs 50, 150 wrapped FRP layers in combination with foamblocks, and foam blocks in combination with intercostal webs 50. Thespacing elements can take on a variety of other shapes, structures,profiles, and materials, so long as the spacing elements effectively fixthe spatial relationships of the inner and outer layers with respect toeach other.

The various foam elements disclosed herein between the inner and outerlayers are of sufficient density, rigidity, and polymer selection to fixthe positions of the inner and outer layers in their respectivepositions relative to each other in panel precursors prior to curing theresin, and to maintain such positioning while resin is being added andcured. Once the resin is cured, the cured resin becomes the primarydeterminant of maintaining the positions of elements in the panel, aswell as the primary determinant of the shape of the panel. Thus, whilenot required of the foam in all instances, the foam can contributesignificantly to the dimensional stability of the panel precursor whilethe panel is being assembled and cured while the resin takes on thatrole once the resin has become cured. Typically, the foam also providessubstantial thermal insulation properties between the inner and outerlayers.

In a simple form, and as illustrated in FIG. 30, a building panel of theinvention includes only inner layer 34, outer layer 36, and studs 23,with foam, such as a foam board, or foam blocks, generally filling thespace between inner layer 34 and outer layer 36.

In an embodiment not shown, studs 23 can extend into the space betweeninner layer 34 and outer layer 36, thus into the main-run portion of thebuilding panel, but not extend across the full thickness “T4” (FIG. 27)of the space defined between the inner and outer surfaces of the foam inthe main run portion of the building panel. Thus, the foam board can beprovided with grooves to receive the studs. It is also contemplated thatthe surface of the foam board can be pre-stressed or otherwise modifiedto receive the studs, or depressed or crushed by the studs as the studsare assembled into the building panel assembly; whereupon a residualinternal resilient force in the building panel assembly may continue toactively push the studs away from foam board 32BD and inwardly towardthe interior of the e.g. building.

Studs 23 can be located over any structurally-reinforcing intercostalbridging member which bridges between the inner and outer layers, asillustrated in FIGS. 24, 26, and 28-29. Where a stud overlies anintercostal bridging member, one or both legs 128 of the stud actstogether with the bridging member whereby no net bending moment iscreated at inner layer 34 adjacent the stud. The gross bending momentscreated in FIG. 24 at layer 34 by stud legs 128 are located on bothsides of the bridging member, and thus tend to cancel each other outbecause of the opposing bending moments created by the respective forceswhereby a stud which straddles a bridging member is treated herein ascreating no net bending moment.

Where, as in FIGS. 28-29, a stud leg 128 directly overlies, and is insubstantial alignment with, a bridging member, the stud leg acts in linewith the bridging member whereby the combination of the stud leg and thebridging member, in combination, act like the web of an I-beam such thatthe bending resistance of the bridging member is additive to the bendingresistance of the stud leg in opposing a force imposed perpendicular tothe inner layer or perpendicular to the outer layer.

Thus, in these embodiments, the stud leg and the intercostal supporteach other in the sense that an intercostal receives loads from e.g.outside layer 36, and transfers substantial portions of the load throughthe panel toward the interior of the building. Inner layer 34 will tendto deflect. But stud leg 128, which is aligned with the direction of theforce vectors is not so readily deflected as the inner layer, and soreceives and resists the load, sharing the load-resisting function andthereby eliminating or substantially reducing any tendency for thewall/panel to bow inwardly between the studs.

Whatever the materials used as the reinforcing fiber, the foam, and theresin, including e.g. resin fillers, all of such elements, including UVinhibitors and fire retardant additives, are chemically and physicallycompatible with all other elements with which they will be in contact,such that no deleterious chemical or physical reaction takes place inwall systems of the invention.

FIGS. 31-36 illustrate a building system foundation wherein a concretefooter under a foundation wall merges with a concrete floor inside thebuilding such that the concrete footer and the concrete floor areintegral with each other and can therefore be formed simultaneously, asa single unitary base 400 of the building, after the wall 10 has beenerected. FIG. 31 is an elevation view and is derived from the elevationview of e.g. FIG. 7, with the stone footer of FIG. 7 being replaced withthe concept of a concrete footer 55 as in FIG. 3.

FIG. 31 shows a wall 10 functioning as a below-grade foundation wall. Inthe embodiment illustrated in FIG. 31, a mini footer 402 illustrated asan 8-inch by 8-inch by 16-inch pre-fabricated concrete block, havingapertures 404 is supported by the natural support base 405, e.g. thenaturally-occurring soil/rock which underlies the building. Suchdimensions are recited for the pre-fabricated concrete block in thecontext that the recited dimensions are the dimensions of commerciallyavailable such blocks. If desired, blocks of other dimensions can beused where available.

In some embodiments, the natural base may be undisturbed. In otherinstances the natural base may be machine-compacted before settingconcrete blocks 402.

As seen in FIG. 31, a plurality of such pre-fabricated concrete blocksare spaced along the length of the wall as spaced mini footers. In astraight-run portion of a wall, such blocks are spaced up to 6 feet (1.8meters) apart, and are leveled individually, and with respect to eachother, to the same tolerances as are allowed for a conventional,separately-poured concrete footer. In the embodiment illustrated in FIG.31, the blocks are registered with ones of the studs 23 such that eachblock underlies one of the studs. With studs 23 spaced on 16-inch (40.6cm) centers, and keeping within the 6 feet (1.8 meters) maximum distanceapart, a block is placed to support the wall under every fourth stud orless.

FIG. 32 illustrates a building system foundation as in FIG. 31 whereinthe prefabricated concrete block, as the mini footer, has been replacedby a poured-in-place solid concrete block, and where reinforcement rods410 have been incorporated into the solid-block mini footer prior to thehardening of the poured-in-place concrete.

FIGS. 34, 35, and 36 illustrate that, irrespective of other spacings ofthe mini footers, a mini footer 402 is positioned under each joint 406between panels 14 in the wall, including in straight-run sections of thewall as in FIG. 34, at each corner where the wall changes direction asillustrated in FIG. 35, and at each shear wall 408 support structure asillustrated in FIG. 36. Thus, a joint is defined by the combination oftwo or more panels which interface through a joint connector such as,without limitation, connectors 140 or connector 160.

Still referring to FIGS. 31-36, steel reinforcing rods 410 extendthrough the mini footers, whether through a solid concrete mini footer,or through apertures 404 in pre-fabricated concrete blocks. Reinforcingrods 410 are tied together in the customary manner with rod ties,including where the wall changes direction such as at wall corners, andat shear wall intersections.

As illustrated in FIGS. 31-33, the bottoms 412 of building panels 14,including the bottoms of studs 23, and thus the bottom of wall 10,interface directly with, and are in part directly supported by,underlying mini footers 402. The bottoms of the building panels extend,and thus the bottom of the wall extends, in a generally straight-line,constant elevation between sequential ones of mini footers 402 wherebythe support of wall 10 by mini footers 402 is intermittent.

Referring to FIGS. 31-33, the elevation of the top 414 of base 400, isdefined by the top of slab 38 and the top of the main footer components55. The elevation of the top 414 of the base is shown in dashed outlinein FIG. 33 because FIG. 33 shows a precursor assembly before ready-mixconcrete, which may be known by such names as “Quik Crete”, has beenpoured in fabricating the main footer body. The top of the base is abovethe elevation of the tops 416 of mini footers 402 such that the bottoms412 of panels 14 and wall 10 extend below the top 414 of base 400, andare thus embedded well below the top of base 400, for example at least 1inch, and up to about 8 inches, below the top of base 400.

Referring to FIGS. 31, 32, and 35, apertures 159 extend throughrespective ones of studs 23. U-shaped, or otherwise angular, anchors 158extend through apertures 159, for example through such apertures inevery “nth” stud. FIGS. 31 and 32 show an anchor 158 extendingdownwardly at an angle of e.g. about 30 degrees to about 60 degrees, forexample about 40 degrees, from horizontal, from a respective aperture159. The downward angle positions the distal portions of the anchorgenerally toward the mid-point of the elevation of the footer portion ofbase 400. Anchors 158 thus make connection with base 400 at the thickestportions of footer component 55 of base 400. As desired,continuous-length runs of anchors, such as at 158B in FIG. 29, orintermittent straight-runs of anchors as at 158A in FIG. 28, can be usedin place of the angular anchors 158.

Either temporary or permanent forms can be used in fabricating base 400.FIG. 33 illustrates use of a permanent footer form 418 with an integralwater drain. A suitable such permanent footer form is available asFORM-A-DRAIN®, available from Certainteed Corporation, Valley Forge, Pa.The FORM-A-DRAINS line of products is a perforated product which isdesigned to receive water which has travelled down the outside of afoundation wall and to channel such water to a discharge venue, thuscontrolling flow of water at the base of the wall.

A below grade sealing membrane 420 is positioned in the corner where thelower portion of the outer surface of wall 10 meets the top of base 400,thus to provide a water barrier on the outside of the wall along thelength of the base of the wall where the FRP wall meets the concretefooter portion of base 400. An exemplary membrane 418 is a rubberizedasphalt product having a puncture resistant core layer. A suitable suchmembrane is available from Amerhart Lumber and Building Distributor,Green Bay, Wis., as BITUTHENE 3000®, made by WR Grace.

FIG. 34 illustrates use of an H-connector 140 at a joint 406, joiningfirst 14A and second 14B panels in a straight-run portion of a wall 10,and wherein reinforcing rods 410 are continuous across the joint betweenpanels 14A and 14B. A mini footer 402 is positioned under, directlyinterfaces with, and supports, each of panels 14A, 14B, and supportsconnector 140.

FIG. 35 illustrates use of a corner connector 160 at a joint 406,joining first 14A and second 14B panels in a right-angle cornerconstruction of the wall 10. In FIG. 35, a mini footer 402 is positionedunder, and directly interfaces with, both of panels 14A, 14B andsupports connector 160. Mini footer 402 is oriented such thatreinforcing rods 410B are aligned with the length of panel 148. A secondpair of reinforcing rods 410A are aligned with the length of panel 14Aand intersect with, and are connected to, the first pair of rods 410B.Where a poured-in-place mini footer is used, reinforcing rods 410A, 410Bcan be bent at right angles and set in the still-flowable concrete, orcan be positioned in the form before the concrete is added to the form,such that respective reinforcing rods traverse both angles of the cornerdefined by panels 14A, 14B.

FIG. 36 illustrates use of a 3-way FRP connector 422 joining an FRPshear wall 424 to a section of the outer wall at a joint 406 betweenpanels 14A and 14B. As with the other joints discussed herein, a minifooter 402 directly interfaces with, and supports, each panel whichforms part of the joint. A mini footer component, as well as a mainfooter component, including reinforcing rods 410, is provided under theshear wall as illustrated.

Shear wall 424 is an FRP wall having opposing first 34 and second 36outermost FRP layers, shown in line format and a foam core 32 betweenlayers 34 and 36. The first and second outermost layers are continuous,top-to-bottom, and extend from the proximal end of the shear wall atconnector 422 to the distal end of the shear wall (not shown). Asappropriate for the stresses to be supported by shear wall 424, one ormore additional reinforcing layers (not shown) can be located betweenthe outermost layers, extending generally parallel to the outermostlayers. Further, the outermost layers, and any such intermediate layer,can be designed and engineered in terms of layer thickness and fiberreinforcement to sustain the magnitude of the shear load which isexpected to be imposed on the shear wall during the anticipated use lifeof the shear wall. The shear wall can include studs 23 (not shown) asdesired protruding from either or both of layers 34 or 36.

The building system foundation illustrated in FIGS. 31-36 is fabricatedgenerally as follows.

First, the area where the building is to be erected is excavated andotherwise conventionally prepared to receive footer material and toprovide for sufficient depth of the footer to support the load of theproposed overlying building structure. In such excavation, all footertrenches are defined, and excavated and leveled to the elevationspecified for the bottoms of the respective footer trenches, and thebottoms of the footer trenches are compacted as necessary in order toestablish a suitable load-bearing surface at the bottoms of the footertrenches.

In addition to the footer trenches about the outer perimeter of thebuilding, footers can be provided inside the outer perimeter of thebuilding to support especially loads imposed on the foundation bydisparate, e.g. distinctly different, overlying portions of the buildingstructure. For example, stone fireplaces, water-bearing structures, andthe like relatively more massive structures, may be supported by footerswhich are inside the outer perimeter of the building. Footers are alsoprovided to support shear walls 408 which support, at e.g. perpendicularangles, the walls which define the outer perimeter of the building.

In addition to the footer trenches, the excavation also establishes theelevation of the area beside the footer where a floor or other slab 38is to be established. Thus, the area to be covered by the slab 38 isexcavated to its desired elevation, and compacted as necessary to definea stable base which can support slab 38 and the magnitude of the loadwhich is expected to be placed on the slab. In addition to establishingthe base which supports the slab, the elevation of the excavation,combined with the specified depth of the slab, defines the elevation ofthe top 426 of the slab, which is the same as the elevation 414 whichdefines the top of the base. Restated, before any concrete is poured ateither the footer or the slab, the natural base is excavated and leveledto the elevation of the bottom of the slab, as well as to the elevationof the bottom of the footer.

As seen in FIGS. 31-32, the elevation which is established to receivethe bottom of the floor slab is generally higher than the elevationwhich is established to receive the bottom of the footer.

Once the footer trenches have been established, a guide is establishedrepresenting the top 416 of each mini footer, for example by stringingan elevation string or cord, or by sighting a laser level, along thelength of the footer location, such that adjacent mini footers which areto cooperate in supporting a given wall can be set at a commonelevation. The tops 416 of mini footers 402 are below the elevationestablished for the top 414 of base 400. Blocks can then be placed inthe footer trenches, spaced from each other by the specified distances,and with the top of each block set at its specified elevation. As eachblock is placed in a footer trench, a puddle of e.g. hand-mixed fluidconcrete is first placed in the footer trench at the location where theblock is to be placed. The block is then placed in/on the puddle ofliquid concrete, the elevation of the top of the block is adjusted asnecessary, and the block is leveled with respect to both the length andwidth of the block, all within and/or on the supporting puddle of liquidconcrete. As part of the block placement process, the block is typicallyoriented such that apertures 404 extend along the length of therespective footer. Where footers intersect, the block is oriented suchthat the apertures extend along the length of a selected one of thefooters.

With the blocks set and leveled, and typically after the concretepuddles have hardened sufficiently, conventional e.g. ⅜ inch (9.5 mm) or½ inch (12.7 mm) steel reinforcing rods 410 are inserted throughapertures 404 so as to extend along the length of the respective footer.Where two footers intersect at e.g. right angles, the reinforcing rods,in the footer which is not aligned with the apertures in the cornerblock, are tied to the rods in the intersecting footer trench, whichrods are aligned with the block.

Where the mini footers are to be poured in place, the trenches areprepared as above. The same guide can be established representing thetop 416 of each mini footer. E.g. wood forms are then set up for each ofthe mini footers at the respective mini footer locations. The top of theform for each mini footer is set at generally the elevation desired forthe respective mini footer. Liquid concrete puddles can be used toassist in getting the tops of the forms to the desired elevations.

The end walls of the forms include apertures adapted to receive steelreinforcing rods 410. The apertures are oriented such that steelreinforcing rods can be inserted through the apertures, and thus throughthe mini footer forms, and extending along the lengths of the respectivefooter trenches. With the mini footer forms in place, steel reinforcingrods are passed into and through the mini footer forms such that thesteel rods collectively extend the full lengths of the footer trenchesto the extent specified. Also if and as specified, overlapping ends ofrespective ones of the steel rods are tied together in the usual mannerfor steel reinforced concrete construction.

With the steel reinforcing rod in place in, through, and between theso-placed mini footer forms, liquid concrete is poured into the minifooter forms, including around the steel reinforcing rods, and allowedto set up and harden. While the liquid concrete is setting up andhardening, final minor adjustments can be hand-worked to provide thedesired finished elevation to the top of the concrete in each minifooter.

The mini-footer concrete is allowed to harden sufficiently to receive atleast initial wall section loading. The forms around the mini footerscan be removed as desired. For example, wood forms can simply be brokenaway from the sides and ends of the mini footers. Where pre-fabricatedconcrete blocks are used as the mini footers, the liquid concretepuddles under the concrete blocks are allowed to set up and hardenbefore a load is applied.

The dimensions and strength capabilities of pre-fabricated concreteblocks are generally determined by others in the sense thatpre-fabricated concrete blocks are a mass-produced commodity itempurchased on the open market. Thus, dimensions and properties aredetermined by the block supplier. Thus, use of pre-fabricated concreteblocks is attended by certain performance limitations, especiallyload-bearing limitations. Load bearing limitations may be importantbecause, as described herein after, the full load of the buildingstructure may be imposed on the mini footers, collectively, before themain component 55 of the footer is fabricated.

The poured-in-place mini footer, on the other hand, has no suchlimitations. Specifically, the dimensions of the poured-in-place minifooter can be specified according to the load-bearing requirements at aspecific location on a specific job site. In addition, the concretecomposition can be specified for the specific location on the specificjob site. Further, the steel reinforcing rod is incorporated into theload-bearing capacity of the poured-in-place mini footer by the timesuch load is applied. Accordingly, load-bearing capabilities are easilyengineered into individual ones of the poured-in-place mini footers.

As a result, a typical poured-in-place mini footer does not have anyopen horizontally-extending apertures corresponding to apertures 404 inprefabricated concrete blocks. And typically the length of a minifooter, along the length of the footer trench, is greater than 8 inches.Rather, the length of a poured-in-place mini footer may extend up to 12inches, up to 18 inches, up to 24 inches, or more. However, the lengthof a mini footer is generally limited to that length which is reasonablyrequired to support the short term load imposed by initial erection ofthe building; and rarely more than half the distance, center-to-center,between adjacent mini footers.

A guide is established representing specific locations for the wallsections. For example, such guide may be established by stringing anelevation string or cord, or by sighting a laser level. Once the guideis established, wall sections and/or wall panels can be placed on themini footers in accord with the specific locations indicated by theguide.

In some embodiments, and optionally, the guide can be supplemented by,or replaced with, physical abutment structure 446 on, mounted to, oradjacent, the mini footer. Such physical structure is illustrated inFIG. 43 as right angle brackets. Such brackets may, for example andwithout limitation, be made using steel or FRP materials. Anotherillustration of physical abutment structure 446 is wood lumber, whichmay be mounted directly to the mini footers, or to the mini footer forms448.

As exemplified by wood boards mounted to mini footer forms 448, abutmentstructure 446 need not be mounted directly to the mini footers 402,though the brackets illustrate that the abutment structure can bemounted directly to the mini footers. Thus, mounting abutment structure446 to the mini footers is optional; while the fixation of the abutmentstructure relative to the mini footers is required where abutmentstructure is used.

Where used, such physical abutment structure is fixed, generallyimmovable, in position relative to the mini footer, and stays in suchfixed position until the building panels, wall, are/is fixedly mountedto the mini footer.

With such optional physical abutment structure fixedly in place relativeto the mini footer as in FIG. 43, individual building panels, or wallsections comprising multiple building panels, are placed on the minifooters, using the abutment structure to assist in aligning the buildingpanels, wall sections on the respective mini footers, such that thebuilding panels extend from mini footer to mini footer along the lengthof the thus-erected walls, for the full length of such wall(s) which areto be constructed using such building panels. In placing a buildingpanel or wall section, the building panel and/or wall section is alignedalong the length of the respective wall such that each end of thebuilding panel is underlain by one of the mini footers. Accordingly,each joint between adjacent such building panels is supported, as toeach building panel involved in forming the joint, by one of the minifooters.

As desired, once a building panel is in place on the respective minifooters, illustrated in FIG. 44, the building panel can be temporarilysecured to the respective mini footers by driving conventional concreteanchors 450 extending through e.g. brackets 446 into the concrete of therespective mini footers; and by driving conventional screws 452 throughbrackets 446 and into the building panel.

The description so far has addressed abutment structure 446 on one sideof the building panel. Such abutment structure can be used to align thepanel at either the inner surface or the outer surface of the buildingpanel. With the panel in place as illustrated in FIG. 44, additionalabutment structure (not shown) can be placed and securely mountedagainst the opposing side of the respective building panel as asupplementary abutment structure, supplementing the holding power of theprimary abutment structure 446.

The purpose of abutment structure 446, and the supplementary abutmentstructure where used, is to hold the building panels against horizontalmovement during the subsequent placement of ready-mix concrete againstthe inside, and optionally the outside, surface(s) of the buildingpanels/wall sections.

Respective wall panels and wall sections are joined to each other suchas at joints 406 using respective ones of the various joining connectorse.g. 140, 160, 422. As illustrated in FIG. 34, studs 23 are so locatedalong the lengths of panels 14 relative to the ends of the panels thatstud spacing across a straight-line joint is the same as the studspacing internally within a given panel.

The thus erected and joined wall sections define the outer perimeterwall 432 of the respective portion, e.g. the entirety, of the buildingas well as internal walls, including shear walls which extend up fromthe mini footers. In addition, footers and walls extending up from thefooters can be provided, according to the specific design of thestructure being built, outside what will become the outer perimeter ofthe building.

If concrete anchors 158A are not already in place in respective ones ofthe studs, apertures 159 are formed in the studs, as necessary,typically below the defined elevation 414 of the top of the base, thusbelow the top of the not-yet-finished footer, and concrete anchors e.g.158A are inserted through apertures 159, thus assembling the anchors tothe respective studs 23, at the desired ones of the studs,correspondingly assembling the anchors to wall 10. Anchors 158A aretypically, but not necessarily, oriented downwardly from apertures 159.Anchors are typically located away from mini footers 402 in order toavoid the potential for interference between downwardly-extendinganchors and the tops of the mini footers. Such interference is suggestedby the overlay of anchor 158A in front of block 402 in FIG. 31.

In some embodiments (not shown), anchors 158A are configured anddirected toward respective ones of reinforcing rods 410 and are tied toreinforcing rods 410 using conventional ties, whereby the studs, and thecorresponding wall sections, are thus tied to reinforcing rods 410 byanchors 158A.

With the walls thus erected and supported by mini footers 402, ifabutment structure 446 is not to be used, the walls can be braced in theusual manner, from outside the outer perimeter of the wall, in order tohold the walls stationary while ready-mix concrete is being poured andworked, and until the concrete hardens sufficiently to hold itsconfiguration without external support.

Referring to FIGS. 31 and 32, and 43-44, footer forms 418, to receivethe main components of the footer, are placed and braced, outwardly ofthe ends 430 of mini footers 402 which extend outwardly from the outerperimeter wall. The tops of footer forms 418 are illustrated in FIGS.31-32 as being at the same elevation as the elevation established forthe top 414 of base 400.

The footer forms may be any desired forms which can be suitably anchoredso as to contain spread of, and retain, the outer edges of the footer asready-mix concrete is caused to flow into, and fill, the space definedfor the mini footer components. Thus, footer 418 forms may be as simpleas conventional temporary wood forms which may be stripped away afterthe concrete of the main footer components has hardened. The footerforms may be more sophisticated, and permanent, forms, e.g. includingwater drainage capability therein, such as the FORM-A-DRAIN® formsdiscussed earlier.

Depending on the load-bearing specifications for the footer, and thelateral positioning of the wall on the tops of mini footers 402, thefooter forms can be as close to the wall as e.g. the ends 430 of theblocks in FIG. 31, or can be spaced farther outwardly from the wall.FIG. 31 shows the footer form in direct contact with end 430 of thecorresponding block.

The next step in creating the monolithic concrete base includes pouringa fluid, e.g. ready-mix, concrete floor about the foundation. Prior topouring such concrete, all utilities which will be encased in theconcrete floor must be first constructed. Such utilities includepressure water lines, grey water drains, any footing drain lines whichmay be directed to a sump inside the building, and may include heatingand/or electrical utilities.

Such utilities are typically constructed/installed after the main shellof the building has been fully constructed/erected and enclosed. Sincethe monolithic concrete base cannot be fabricated until such utilitiesare in place, the mini footers must support the full weight of suchenclosed building structure without benefit of any support of thenot-yet-installed main footer components. Accordingly, the mini footers402 are engineered to sustain such load temporarily during the period inwhich the building will be constructed.

Once the floor utilities are in place, as a final step in preparationfor pouring fluid ready-mix concrete in fabricating the monolithicconcrete base, the elevation of the excavation which is to be overlaidby slab 38 is confirmed at various spaced locations about the areadefined for slab 38, and is checked for suitable density/tamping; andany disturbance of the natural base which may have occurred subsequentto the excavation and other preparations for the slab, is repaired inlate-stage preparation for the pouring of fluid ready-mix concrete.

With the mini footers, the wall sections/walls, the reinforcing rodmatrix, the anchors, the forms, the shear walls, and the floor utilitiesand any required floor supports in place, with the walls suitably bracedagainst lateral movement, with the bottoms of the wall sections/walls onthe mini footers below the elevation 414 of the top of the prospectiveslab/footer/base, and above the bottoms of the footer trenches, and withthe elevation of the natural base to be overlain by slab 38 established,confirmed, tamped, and otherwise prepared, the so-assembled precursor isready to receive fluid ready-mix concrete. Substantial openings existbetween adjacent ones of the mini footers, and between the bottoms ofthe wall sections and the bottoms of the footer trenches.

Fluid ready-mix concrete is then poured into the so-prepared space to beoccupied by slab 38 and footers 55. Where the slab is disposed inwardlyinto the interior of the building being constructed, the ready-mixconcrete is typically delivered inside the area enclosed by outer wallperimeter 432, and is flowed/worked outwardly under the wall panels,wall sections, in the footer trenches to the outermost regions of thefooter trenches, including into and through any apertures 404 in themini footers, about the ends of mini footers 402, and tooutwardly-disposed footer forms 418. Ready-mix concrete may be delivereddirectly to the footer trenches on the outside of the perimeter wall,and to any slab outside the perimeter wall, as desired.

The fluid ready-mix concrete is filled to the tops of forms 418, whichis consistent with the elevation of the top 426 of slab 38 and thus theelevation of the top 414 of base 400.

Given that the bottoms of the wall sections are resting on the tops 416of mini footers 402, given that the tops of the footer forms 418 are athigher elevations than the tops 416 of the mini footers, and given thatthe top 414 of base 400 is at a higher elevation than the tops of themini footers, the bottoms of the wall sections, and thus the bottom ofthe walls, are below the top 414 of the base. Accordingly, the bottom ofthe wall is embedded in the poured concrete base, and is typically about1 inch (2.5 cm) to about 3 inches (7.6 cm) below top 414 of the pouredconcrete base. Once the concrete sets/hardens, the wall and the concretebecome part of a single monolithic structure, wherein the base intowhich the wall is held, includes at least one slab which is unitary withthe footer which underlies the wall. In addition, anchors 158 areembedded in the hardened concrete and may, further, have been tied toreinforcing rods 410. Thus, once the concrete sets/hardens, the footer,the slab, and the wall are all part of a single structural unit. Thefooter includes mini footers 402, the steel reinforcing material, andthe main components of the footer which extend over, between, and aroundthe mini footers and the steel reinforcing material.

After the concrete has been poured, the concrete is worked to providethe desired finish to the top surface of base 400. In some embodiments,the surface 426 of that portion of the footer which is disposedoutwardly of the building from outer layer 36 of the wall, is finishedwith a downward slope away from the outer surface of the wall. A sealingmembrane 420 may be applied to the outside surface of wall 10, at thebase of the wall and draping over the top surface of footer 55, asgenerally illustrated in FIGS. 31 and 32. A suitable adhesive can beused as desired to mount membrane 420 to the outer surface 56 of wall10. In embodiments, where the outer footer form is adapted to receivewater from the outer surface of the wall, to channel such water anddischarge such water away from the wall, the lower end of membrane 420is typically terminated proximate the footer form. Where other means areused to receive, channel and discharge water from the outer surface ofthe wall, sealing membrane 420 is terminated proximate such watercapture elements.

As illustrated in FIGS. 31 and 32, after the base has been poured, amonolithic body of concrete encompasses both the main components of thefooter(s) and the slab 38. To the extent discrete footer elements arespaced from, not contiguous with, the outer perimeter footer, but arelocated inwardly in the building of the outer perimeter footer, namelyinside the building, such discrete footer elements are still part of themonolithic body of concrete which defines both the footer elements andthe slab, of base 400.

Even where a structure may not be roofed-over, the same principles canbe used to fabricate any combination of monolithic footer, slab andwalls.

While the embodiments illustrated in FIGS. 31-36 illustrate abelow-grade foundation, the principles illustrated there can be used aswell in grade-level foundations. Thus, for a slab-on-grade structure,the base 400, including footer 55 and slab 38 are developed at generallythe natural grade of the ground surrounding the construction area ormodestly above such grade. In such instance, it may be desirable tofabricate a garage apron or parking area immediately beside the buildingstructure. Such garage apron can be fabricated at the same time, and aspart of the same structure, as the footer by preparing the elevation ofthe natural base outside the building structure in the same manner ashas been described for preparing the natural base for a slab inside thebuilding.

Thus, the same principles can be used to fabricate the footer, the slabinside the building, and the slab outside the building, all as a singleunit, and all fabricated at the same time.

Where a slab is being fabricated outside the building, any desired formscan be used to define the outer perimeter of such slab.

Reinforcing rods 410 can be relocated to other suitable locations solong as such rods still provide the necessary strength enhancements tothe concrete in footer 55. Further, the material of rods 410 can bemodified as desired, whereby rods 410 can be coated with any of avariety of polymeric materials, or can be fabricated exclusively fromFRP materials.

The embodiments of FIGS. 31-36 illustrate the principle of supporting afoundation wall on spaced mini footers which later become part of thecompleted footer/floor base when fluid concrete, such as but not limitedto ready-mix concrete, is flowed under the wall in fabrication of amonolithic structure which embodies both a slab and a footer. Therespective embodiments have been illustrated using the FRP walls andwall structures disclosed herein. However, the principles of firstsupporting a wall on spaced support blocks, above the bottom of thespace allocated to the footer, and then flowing concrete under such wallin fabrication of the footer and thus using such flowed concrete, oncehardened, to support the wall along the full length of the footer, canbe practiced with any wall structure which can be supported on spacedmini footers until such time as the fluid concrete can be flowed underthe wall and hardened, such that the thus-poured concrete supports thebottom of the wall along that portion of the full length of the wallwhich is not supported by the earlier-placed mini footers. The resultingfooter has first and second sets of footer elements, namely the minifooters supporting respective ones of the wall elements. The first setof footer elements has been fabricated before the placing of the wallelements. The second set of footer elements, namely the main footercomponents, has been fabricated after the placing of the wall elements.Since the wall is already supported by the mini footers before the mainfooter components are fabricated, initially the relative loadingsupported by the main footer components is less than the relativeloading supported by the mini footers. However, as the wall is furtherloaded after the concrete in the main footer components has cured, themain footer components pick up incremental portions of the load whichare more representative of the fractions of the wall which are underlainby the main footer components.

Still referring to FIGS. 31-36, the concrete base 400 is illustrated asa monolithic, single-unit mass of concrete. As desired, an inner footerform (not shown) can be set inwardly of the inner surface of the wall,such as inwardly of inner surface 25, or inwardly of end panels 44 ofthe studs, such that footer 55 can be poured separately from slab 38.Namely, with the inner footer forms in place, fluid concrete can beflowed into the footer forms, including under the bottom of the so-setwall which is resting on the mini footers. The fluid concrete is workedand allowed to harden. Subsequently, the slab 38 is poured. The innerfooter forms may or may not be removed before the slab is poured.

In the alternative, forms can be set up defining the outer perimeter ofthe slab; and concrete poured into the slab area and allowed to harden,thus establishing the dimensions of the slab before footer concrete ispoured. After the slab concrete is set up, the footer is poured as aseparate step, but again causing the concrete to flow under the bottomof the previously-set foundation wall.

While the description so far has illustrated the flowing of the fluidconcrete under the wall from the inside of the wall, e.g. from innersurface 57 toward outer surface 56, in some instances, the concrete isplaced in the footer space which is disposed outwardly of the wall andis then caused to flow under the wall and toward the inner surface ofthe wall. Thus, the concrete can be flowed under the foundation wallfrom either the inner side of the wall or from the outer side of thewall. The selection of which side of the wall is used as the initiatinglocation depends on the ease of accessing the inner or outer surface ofthe wall versus the amount of space available between the respectiveinner or outer surface of the wall and the respective footer form onthat side of the wall.

FIGS. 40-41 illustrate use of building panels of the invention wheresoil or other backfill material is backfilled against a wall 10 toproximate a window 271. In such embodiments, the soil applies a lateralload to the outer surface of wall 10, tending to cause the wall todeflect inwardly. In such embodiments, a sill cap 440 can be placed inthe window rough opening, at the lower sill as illustrated in FIGS.40-41. As placed in the window rough opening, sill cap 440 is adownwardly-open elongate U-shaped FRP channel extending along the lengthof the wall. Sill cap 440 has a base panel 442, and opposing side panels444. Base panel 442 extends along the length of the panel, forsubstantially the full length of the window opening, and is orientedhorizontally. Side panels 444 extend downwardly from opposing elongateedges the base panel, substantially the fill length of the windowopening. Accordingly, the open side of the “U-channel” faces downwardlyand extends substantially the full length of the window opening, asillustrated.

As illustrated in FIG. 40, spacing of side panels 444 from each other issuch that, with the sill cap installed on the lower surface of thewindow opening, the side panels are in interfering contact with theouter surface 56 of wall 10 and with the outermost surfaces of endpanels 44 of studs 23.

Base panel 442 and side panels 444 are specified as rigid members whichcan absorb lateral stresses imposed on wall 10 from backfill materialpushing against the outer surface of the wall, thus to attenuatetendency of the wall to bend at window 27. The thicknesses, materials,fiber reinforcements in sill cap 440 can be the same as for studs 23,inner layer 34, and/or outer layer 36. Thus the same fiber reinforcedpolymer materials can be used. The same fiber schedules can be used. Thesame thicknesses can be used. In typical such sill caps, the base paneland/or the side panels can be about 0.13 inch (3.3 mm) thick; but thethicknesses and fiber schedules can be adjusted to account foranticipated side loads.

Building panels and walls of the invention are essentially almost waterproof; and such water proof characteristic is not generally affected byhurricane-driven rain. Outer layer 36 is, itself, very water resistant.While layer 36 is quite difficult for water to penetrate, even if layer36 is breached, the foam blocks 32 or foam board 32BD are very waterresistant in that the individual cells of the foam 32 are typicallydosed cells. If the foam layer is also breached, inner layer 34 is alsovery water resistant. In addition, where a weaving layer is used, beforethe breaching force reaches layer 34, the breaching force must passthrough weaving layer 50, which is another layer which is difficult forwater to penetrate, whether layer 50 is encountered adjacent layer 36 oradjacent layer 34. In any event, any breaching force has to penetratemultiple very water resistant layers. The FRP structures which do notinclude foam are similarly-effective barriers to water penetration.

Those skilled in the art will now see that certain modifications can bemade to the apparatus and methods herein disclosed with respect to theillustrated embodiments, without departing from the spirit of theinstant invention. And while the invention has been described above withrespect to the preferred embodiments, it will be understood that theinvention is adapted to numerous rearrangements, modifications, andalterations, and all such arrangements, modifications, and alterationsare intended to be within the scope of the appended claims.

To the extent the following claims use means plus function language, itis not meant to include there, or in the instant specification, anythingnot structurally equivalent to what is shown in the embodimentsdisclosed in the specification.

Having thus described the invention, what is claimed is:
 1. Afiber-reinforced polymeric load-bearing building panel having a length,a top and a bottom, and comprising: (a) an outer fiber-reinforcedpolymeric layer about 0.10 inch thick to about 0.30 inch thick, saidouter layer comprising a first set of continuous fibers in a firstreaction-cured resin composition, said outer layer defining a firstoutermost surface of said building panel; (b) an inner fiber-reinforcedpolymeric layer about 0.10 inch thick to about 0.30 inch thick, saidinner layer comprising a second set of continuous fibers in a secondreaction-cured resin composition, said inner layer defining a secondoutermost surface of said building panel; and (c) a plurality ofload-bearing studs, spaced along the length of said building panel andextending, from said inner layer, away from the second outermost surfaceto end panels (130) of said studs, including away from said buildingpanel, said studs extending along the height of said building panel, andhaving walls, defining outer surfaces of said studs, about 0.10 inchthick to about 0.30 inch thick, said walls of said studs comprising athird set of continuous fibers in a third reaction-cured resincomposition, said building panel having a thickness between said innerlayer and said outer layer, excluding any dimensions of said studs, ofabout 2 inches to about 5 inches, said building panel having a mass ofno more than 18 pounds per foot of height per linear foot length of saidbuilding panel, and a vertical crush resistance capacity of at least2000 pounds per linear foot length of said building panel when testedaccording to ASTM E72, and using a safety factor of
 3. 2. A buildingpanel as in claim 1, having a bending resistance capacity, whensubjected to uniform loading in accord with ASTM E72, of up to about 250pounds per square foot surface area of said outer layer, of no more thanL/240.
 3. A building panel as in claim 1, having a bending resistancecapacity, when subjected to uniform loading in accord with ASTM E72, ofup to about 325 pounds per square foot surface area of said outer layer,of no more than L/180.
 4. A building panel as in claim 1, said buildingpanel having a horizontally-directed bending resistance capacity, whensubjected to uniform loading in accord with ASTM E72, of up to about 400pounds per square foot surface area of said outer layer, of no more thanL/120.
 5. A building panel as in claim 1, said building panel having avertical, top-to-bottom applicable crush resistance capacity of at least4000 pounds per linear foot length of said building panel, using asafety factor of
 3. 6. A building panel as in claim 1, said buildingpanel having a vertical, top-to-bottom applicable crush resistancecapacity of at least 6000 pounds per linear foot length of said buildingpanel, using a safety factor of
 3. 7. A building panel as in claim 1,said building panel having a vertical, top-to-bottom applicable crushresistance capacity of at least 8000 pounds per linear foot length ofsaid building panel, using a safety factor of
 3. 8. A building panel asin claim 1 wherein said building panel, under a top-to-bottom loaddistributed between said outer layer and said end panels of said studsaccording to ASTM E72, deflects toward said outer layer.
 9. A buildingpanel as in claim 1 wherein said building panel, under a top-to-bottomload, distributed between said outer layer and said end panels of saidstuds according to ASTM E72, deflects toward said outer layer, and has ahorizontally-directed bending resistance capacity, when subjected touniform transverse loading of up to about 250 pounds per square foot inaccord with ASTM E72, of no more than L/240.
 10. A building panel as inclaim 9 wherein said building panel has a vertical crush resistancecapacity, to catastrophic panel failure, when tested in accord with ASTME72, of at least 20,000 pounds per linear foot length of said buildingpanel.
 11. A building panel as in claim 1 wherein said building panelhas a vertical crush resistance capacity, to catastrophic panel failure,when tested in accord with ASTM E72, of at least 25,000 pounds perlinear foot length of said building panel.
 12. A building panel as inclaim 1 wherein at least 50 percent by weight, of at least one of saidfirst, second, and third sets of fibers, collectively, extends in adirection within 15 degrees of the top-to-bottom height of said buildingpanel.
 13. A building panel as in claim 1 wherein at least about 70percent by weight, of each of said first, second, and third sets offibers extends in a direction within 15 degrees of the top-to-bottomheight of said building panel.
 14. A building panel as in claim 1wherein at least 50 percent by weight of each of said first, second, andthird sets of fibers extends in a direction which is substantiallyaligned with, thus parallel to, the top-to-bottom height of saidbuilding panel.
 15. An upright outer wall in a building comprising oneor more building panels as in claim
 1. 16. A building comprising anouter wall as in claim 15, as a foundation wall exposed to soil backfillloading, and an overlying building structure bearing down on saidfoundation wall, wherein horizontal deflection of said foundation wall,when under such building load, is directed outwardly toward the soilbackfill and is limited to no more than L/120 where such overlying loadis no more than 5000 pounds per linear foot of said foundation wall. 17.A fiber-reinforced polymeric load-bearing building panel having alength, a top and a bottom, and comprising: (a) an outerfiber-reinforced polymeric layer about 0.10 inch thick to about 0.30inch thick, said outer layer comprising a first set of continuous fibersin a first reaction-cured resin composition, said outer layer defining afirst outermost surface of said building panel; (b) an innerfiber-reinforced polymeric layer about 0.10 inch thick to about 0.30inch thick, said inner layer comprising a second set of continuousfibers in a second reaction-cured resin composition, said inner layerdefining a second outermost surface of said building panel; and (c) aplurality of load-bearing studs, spaced along the length of saidbuilding panel and extending, from said inner layer, away from thesecond outermost surface to end panels (130) of said studs, includingaway from said building panel, said studs extending along the height ofsaid building panel, and having walls, defining outer surfaces of saidstuds, about 0.10 inch thick to about 0.30 inch thick, said walls ofsaid studs comprising a third set of continuous fibers in a thirdreaction-cured resin composition, said building panel having a thicknessbetween said inner layer and said outer layer, excluding any dimensionsof said studs, of about 2 inches to about 5 inches, said building panelhaving a mass of no more than 18 pounds per foot of height per linearfoot length of said building panel, and wherein said building panel,under a top-to-bottom load distributed between said outer layer and saidend panels of said studs according to ASTM E72, deflects between the topof said building panel and the bottom of said building panel, towardsaid outer layer.
 18. A building panel as in claim 17 wherein thedeflection of said building panel is no more than L/120 when tested inaccord with ASTM E72 at an absolute loading of 15,000 pounds per linearfoot length of said building panel.
 19. An upright outer wall in abuilding comprising one or more panels as in claim
 17. 20. A buildingcomprising an outer wall as in claim 19, as a foundation wall exposed tosoil backfill loading, and an overlying building structure bearing downon said foundation wall, wherein horizontal deflection of saidfoundation wall, when under such building load, is directed outwardlytoward the soil backfill and is limited to no more than the equivalentof L/120 when no external resistance is applied, and where suchoverlying load is no more than 5000 pounds per linear foot of saidfoundation wall.
 21. A fiber-reinforced polymeric load-bearing buildingpanel having a length, a top and a bottom, and comprising: (a) an outerfiber-reinforced polymeric layer about 0.10 inch thick to about 0.30inch thick, said outer layer comprising a first set of continuous fibersin a first reaction-cured resin composition, said outer layer defining afirst outermost surface of said building panel; (b) an innerfiber-reinforced polymeric layer about 0.10 inch thick to about 0.30inch thick, said inner layer comprising a second set of continuousfibers in a second reaction-cured resin composition, said inner layerdefining a second outermost surface of said building panel; and (c) aplurality of fiber-reinforced polymeric load-bearing studs comprising athird set of continuous fibers in a third reaction-cured resincomposition, said studs being spaced along the length of said buildingpanel and extending away from said building panel, including away fromthe second outermost surface; and at least about 50 percent by weight,of at least one of said first, second, and third sets of fibers,collectively, extending in a direction within 15 degrees of thetop-to-bottom height of said building panel.
 22. A building panel as inclaim 21 wherein at least 50 percent by weight of each of said first,second, and third sets of fibers extend in a direction within 15 degreesof the top-to-bottom height of said building panel.
 23. A building panelas in claim 21 wherein said building panel has a mass of no more than 18pounds per linear foot length of said building panel per foot height ofsuch one-foot length.